Ford Fusion Hybrid 2012 Workshop Repair and Service Manual Part2

2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual
35. NOTE: LH shown, RH similar.
Remove the 2 front subframe nuts.
36. Lower the subframe assembly from the vehicle.
37. Remove the 2 fasteners and the inspection cover.
38. Remove and discard the 4 torque converter nuts.
39. Disconnect the transmission fluid cooler hoses from the transmission fluid cooler tubes.
40. Support the transaxle with a suitable transmission jack. Secure the transaxle to the transmission jack
with a safety strap.
41. Remove the 7 torque converter housing bolts and remove the transaxle.
Transaxle 3499
42. If installing a new transaxle, the transmission fluid cooler will need to be backflushed and cleaned.
Carry out transmission fluid cooler tube backflushing and cleaning. For additional information, refer
to Transmission Fluid Cooler - Backflushing and Cleaning in this section.
Transaxle 3500
SECTION 307-01A: Automatic 2012 Fusion, MKZ, Fusion Hybrid, MKZ

Transaxle/Transmission - Aisin AW21 Hybrid Workshop Manual
DISASSEMBLY AND ASSEMBLY OF
Procedure revision date: 06/03/2011
SUBASSEMBLIES
Torque Converter Hub Seal
Special Tool(s)
Installer, Fluid Pump Seal

307-548
Remover, Input Shaft Oil Seal

308-375
Slide Hammer
307-005 (T59L100-B)
Disassembly
1. Remove the transaxle. For additional information, refer to Transaxle in this section.
2. Remove the torque converter.
3. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the torque converter hub seal.
Assembly
1. Position the torque converter hub seal in place.
Torque Converter Hub Seal 3501

2. Using the Fluid Pump Seal Installer, install the torque converter hub seal.
3. Install the torque converter.
4. Install the transaxle. For additional information, refer to Transaxle in this section.
Torque Converter Hub Seal 3502


SUBASSEMBLIES
Torque Converter
Disassembly
1. Remove the transaxle. For additional information, refer to Transaxle in this section.
2. Remove the torque converter.
Assembly
1. Install the torque converter.
2. Install the transaxle. For additional information, refer to Transaxle in this section.
Torque Converter 3503



INSTALLATION Procedure revision date: 06/03/2011
Transaxle
Special Tool(s)
Eye, Engine Lift

303-1245
Bar, Engine Spreader

303-1246
Powertrain Lift With Tilting Plate

300-OTC-1585AE
Support Bar, Engine

303-F072
Vehicle Communication Module (VCM)

and Integrated Diagnostic System (IDS)
software with appropriate hardware, or
equivalent scan tool
Material
Item Specification
Motorcraft® Premium Automatic WSS-M2C924-A
Transmission Fluid
XT-8-QAW (US);
CXT-8-LAW12 (Canada)
Multi-Purpose Grease ESB-M1C93-B
XG-4 and/or XL-5
Threadlock and Sealer WSK-M2G351-A5
TA-25
NOTICE: The use of any transmission fluid other than what is recommended for this transaxle will
cause transaxle damage.
NOTE: If the transaxle was overhauled, or if installing a new transaxle and the transmission fluid cooler has
not been flushed, flush the transmission fluid cooler at this time. For additional information, refer to
Transmission Fluid Cooler - Backflushing and Cleaning in this section.
All vehicles
1. Secure the transaxle to a suitable transmission jack with a safety strap.
2. Prior to installing the transaxle, apply multi-purpose grease to the torque converter pilot hub.
Transaxle 3505
3. Position the transaxle to the back of the engine.
4. Install the 7 transaxle-to-engine bolts.

• Tighten to 48 Nm (35 lb-ft).
5. Connect the transmission fluid cooler hoses to the transmission cooler tubes.
6. Install 4ew torque converter nuts.

7. Position the inspection cover in place and install the 2 fasteners.
Transaxle 3506
8. Using the Powertrain Lift With Tilting Plate, raise the subframe into the installed position.
Install the 2 front subframe nuts.
Position the subframe brackets and install the 4 bolts finger-tight.
Install the 2 rear subframe nuts.
Transaxle 3507
Tighten the 4 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
13. NOTICE: Use care when handling the steering gear to avoid unseating the steering gear/dash
seal. If the steering gear/dash seal becomes unseated, water and foreign material may enter the
passenger compartment and damage to the vehicle interior can occur.
Position the steering gear.
1. Install the 3 steering gear mounting bolts.

2. Tighten to 107 Nm (79 lb-ft).
14. Install the 3 power steering return line bolts.

• Tighten to 9 Nm (80 lb-in).
Install the stabilizer bar links and nuts to the struts.
Transaxle 3508
Install the tie-rod ends and nuts.

• Install new cotter pins.
17. NOTE: Front Wheel Drive (FWD) shown, All-Wheel Drive (AWD) similar.
Install the 2 roll restrictor bracket bolts.
All-Wheel Drive (AWD) vehicles
18. Install the Power Transfer Unit (PTU). For additional information, refer to Section 308-07B .
Front Wheel Drive (FWD)
19. Install the exhaust flexible pipe. For additional information, refer to Section 309-00 .
20. Install the RH intermediate shaft. For additional information, refer to Section 205-04 .
All vehicles
21. Install the LH halfshaft. For additional information, refer to Section 205-04 .
22. Install the LH splash shield and the 6 pin-type retainers (4 shown).
23. Position the LH fender splash shield and install the 4 screws.
Transaxle 3509
24. Install the RH splash shield and the 6 pin-type retainers (4 shown).
25. Position the RH fender splash shield and install the 4 screws.
26. Apply threadlock and sealer to the threads and install the transaxle support insulator bracket, the 2
nuts and the bolt.
1. Tighten the bolt to 80 Nm (59 lb-ft).
2. Tighten the nuts to 90 Nm (66 lb-ft).
27. Using the Engine Support Bar, raise the transaxle. Apply threadlock and sealant to the threads and
install the transaxle support insulator through bolt.
28. Remove the Engine Support Bar and Engine Spreader Bar.
Transaxle 3510
29. Remove the Engine Lift Eye from the LH cylinder head.
30. Install the 4 upper transaxle-to-engine bolts.

31. Position the 2 ground straps in place and install the 2 ground strap bolts.
32. Connect the wiring harness fasteners on the torque converter housing stud bolt and the starter motor.
33. Connect the Transmission Control Module (TCM) electrical connector.
Transaxle 3511
34. Position the selector lever cable bracket in place and install the 2 bolts and the nut.
35. Connect the selector lever cable end.
36. Remove the transmission fluid fill plug.
37. Fill the transaxle with clean transmission fluid.
38. Install the transmission fluid fill plug.

39. Install the upper intake manifold. For additional information, refer to Section 303-01C .
40. Install the starter. For additional information, refer to Section 303-06 .
41. Install the Air Cleaner (ACL) and outlet tube. For additional information, refer to Section 303-12C .
Transaxle 3512
42. Remove the transmission fluid level indicator and make sure that the transaxle has transmission fluid
in it.
43. With the transaxle in PARK, the vehicle on a level surface, the engine at idle (680-780 rpm) and foot
pressed on the brake, move the selector lever through each gear and allow engagement of each gear.
Place the selector lever back in the PARK position.
44. Wipe the transmission fluid level indicator cap and remove the transmission fluid level indicator.
45. Wipe the transmission fluid level indicator with a clean cloth.
46. NOTE: In order to get an accurate transmission fluid level reading the vehicle should be on a level
surface. Idle the engine to reach the normal operating temperature. Using the scan tool, verify that the
transaxle is at normal operating temperature 60°C-70°C (140°F-158°F), prior to adjusting the
transmission fluid level.
If transmission fluid needs to be added, add transmission fluid in 0.25L (1/2 pt) increments through
the transmission fluid fill plug located on the top of the transaxle near the transmission fluid level
indicator. Do not overfill the transmission fluid. Install the transmission fluid level indicator back in
the transmission fluid filler tube until it is fully seated, then remove the indicator. The transmission
fluid level should be at the upper most mark on the transmission fluid level indicator. Only fill to the
upper most mark on the transmission fluid level indicator. Do not overfill. Damage to the transaxle
will occur.
47. NOTE: The correct transmission fluid level at normal operating temperature of 60°C-70°C
(140°F-158°F) is between the top 2 marks on the transmission fluid level indicator.
Fill the transaxle to the correct transmission fluid level.
48. NOTE: The correct transmission fluid level at cold operating temperature of 15°C-25°C (59°F-77°F)
is at the bottom mark on the transmission fluid level indicator.
If the Transmission Fluid Temperature (TFT) is low, fill the transaxle with transmission flold range
on the transmission fluid level indicator. Recheck the transmission fluid level when the transaxle has
reached the normal operating temperature.
Transaxle 3513
49. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile
Correction procedure, following the on-screen instructions.
Transaxle 3514
SECTION 307-01B: Automatic 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid
Transaxle/Transmission - 6F35 Workshop Manual
SPECIFICATIONS Procedure revision date: 03/20/2012
Material
Item Specification Fill

Capacity
Dye-Lite® ATF/Power Steering - -
Fluid Leak Detection Dye
164-R3701 (Rotunda)
Motorcraft® MERCON® LV MERCON® LV 8.5L (9 qt)
Automatic Transmission Fluid
XT-10-QLVC
Multi-Purpose Grease ESB-M1C93-B -
XG-4 and/or XL-5
Threadlock and Sealer WSK-M2G351-A5 -
TA-25
Ultra Silicone Sealant - -
TA-29
General Specifications
Item Specification
Transaxle Weight 86 kg (189 lb)
Solenoid Operation Chart

Shift Solenoid
Base Selector PCM SSA (VFS) SSC (VFS) SSD (VFS) SSE TCC
Lever Commanded NL (CB SSB (VFS) NL (CB NH (CB (On/Off) (VFS)
Position Gear 1,2,3,4) NH (3,5,R) 2,6) L,R/C 4,5,6) NC NL
P P Off On Off Off On Off
R R Off Off Off Off On Off
N N Off On Off Off On Off
D 1 On On Off Off a On b Off
2 On On On On Off Off
3 On Off Off On Off Off
4 On On Off Off Off On/Off
5 Off Off Off Off Off On/Off
6 Off On On Off Off On/Off
L 1 On On Off Off On Off
a Turns on above 8 km/h (5 mph).
b Turns off above 8 km/h (5 mph).
CB = Clutch brake
Transaxle 3515
NC = Normally closed
NH = Normally high
NL = Normally low
Clutch Application Chart
Direct (C Overdrive (C Forward (CB Low/ Reverse Inter- mediate

Gear 3,5,R) 4,5,6) 1,2,3,4) (CB L,R) (CB 2,6) One-Way
1st X Xa X
2nd X X O/R
3rd X X O/R
4th X X O/R
5th X X O/R
6th X X O/R
Reverse X X
a Turns off above 8 km/h (5 mph).
CB = Clutch brake
O/R = Overrunning
Line Pressure Chart
Gear Line
Pressures at Idle a
P 338-379 kPa (49-55 psi)
R 621-689 kPa (90-100 psi)
N 338-379 kPa (49-55 psi)
D 338-379 kPa (75-85 psi)
L 338-379 kPa (75-85 psi)
Pressure at Wide Open
Throttle (WOT) Stall a
P 338-379 kPa (49-55 psi)
R 1,868-2,068 kPa
(271-300 psi)
N 338-379 kPa (49-55 psi)
D 1,868-2,068 kPa
(271-300 psi)
Transaxle 3516
L 1,868-2,068 kPa
(271-300 psi)
a All pressures are approximate.
Stall Speed Chart
Selector Lever Engine rpm

Drive 2.5 2,200-2,300
Drive 3.0 2,400-2,500
Gear Ratio Chart
Gear Ratio
1st/low 4.584:1
2nd 2.964:1
3rd 1.912:1
4th 1.446:1
5th 1:1
6th 0.746:1
Reverse 2.94:1
Shift Speeds 2.5L
Throttle Position Range Shift KM/H MPH

Light D 1-2 11-16 7-10
Throttle a D 2-3 21-27 13-17
D 3-4 29-37 18-23
D 4-5 45-56 28-35
D 5-6 72-90 45-56
Medium D 1-2 27-43 17-23
Throttle a D 2-3 42-55 26-34
D 3-4 58-77 36-48
D 4-5 77-106 48-66
D 5-6 135-177 84-110
Heavy D 1-2 51-66 32-41
Throttle a D 2-3 79-100 49-62
D 3-4 113-143 70-89
D 4-5 150-190 93-118
D 5-6 201-245 125-152
Transaxle 3517
a Do not exceed the speed limit.
Shift Speeds 3.0L

Light D 1-2 13-18 8-11
Throttle a D 2-3 19-26 12-16
D 3-4 29-37 18-23
D 4-5 45-56 28-35
D 5-6 72-90 45-56
Medium D 1-2 32-42 20-26
Throttle a D 2-3 48-61 30-38
D 3-4 63-82 39-51
D 4-5 80-108 50-67
D 5-6 117-159 73-99
Heavy D 1-2 58-72 36-45
Throttle a D 2-3 85-106 53-66
D 3-4 126-156 78-97
D 4-5 151-192 94-119
D 5-6 217-261 135-162
Torque Specifications
Description Nm lb-ft lb-in

Battery Junction Box (BJB) support bracket 10 - 89
Clutch support tower bolts 12 - 106
EGR valve bracket bolts 10 - 89
Electronic Power Assist Steering (EPAS) ground bolt 12 - 106
Line pressure tap plug 12 - 106
Lube funnel hold-down bracket bolts 12 - 106
Main control cover bolts/stud bolts 12 - 106
Manual control lever nut 24 18 -
Main control stud nut a - - -
Main control-to-case stud 10 - 89
Main control valve body bolts a - -
Output Shaft Speed (OSS) sensor bolt 10 - 89
Pump assembly-to-torque converter housing bolts 35 26 -
RH exhaust manifold heat shield bolts 11 - 97
Roll restrictor bolts 90 66 -
Roll restrictor bracket bolts 90 66 -
Selector lever cable bracket nuts 12 - 106
Transaxle 3518
Separator plate bolts 10 - 89

Solenoid body bolts 10 - 89
Solenoid body-to-valve body bolts 10 - 89
Stabilizer bar link nuts 40 30 -
20 - 177
Subframe nuts 150 111 -
Subframe bracket-to-body bolts 103 76 -
Torque converter housing bolts 48 35 -
Torque converter nuts 40 30 -
Transaxle case-to-torque converter housing bolts 24 18 -
Transaxle support insulator bolts 62 46 -
Transaxle support insulator bracket bolt 63 46 -
Transaxle support insulator bracket nuts 63 46 -
Transaxle support insulator through bolt 150 111 -
Transmissio 12 - 106
Transmission fluid cooler tube bracket nuts 9 - 80
Transmission fluid drain plug 12 - 106
Transmission fluid filler tube nut 11 - 97
Transmission Range (TR) sensor detent spring bolt 13 - 115
Turbine Shaft Speed (TSS) sensor bolt 10 - 89
a Refer to the procedure for the specification.
Transaxle 3519
DESCRIPTION AND OPERATION Procedure revision date: 06/03/2011
Transaxle Description
This automatic transaxle is a 6-speed transaxle with electronic shift control. It is designed for operation in a
transverse powertrain for Front Wheel Drive (FWD) and All-Wheel Drive (AWD) vehicles.
This transaxle has a 4-element torque converter design, which includes a Torque Converter Clutch (TCC) and
a geartrain with 3 planetary gearsets.
The hydraulic control system of this transaxle uses 7 electronically controlled solenoids for:
• Shift feel (through line pressure control and shift pressure control)
• Shift scheduling and timing
• TCC operation
p;
Transaxle Description 3520

Identification Tags
Identification Tag Location
Item Part Number Description

1 7G342 Solenoid body identification tag
2 7B148 Transaxle identification tag
Transaxle Identification Tag
Description
1 Transaxle part number
2 Bar code 1
3 Assembly plant line shift
4 Transaxle build date (DDMMYY)
5 Transaxle serial number
6 Bar code 2
When servicing the transaxle, use the transaxle identification tag located on top of the transaxle case.
Identification Tags 3521

Original Solenoid Body Tag
Item Description
1 Thirteen-digit solenoid body strategy
2 Seven-digit solenoid body identification
The solenoid body strategy is a file that is programmed into the PCM to control the shift, Line Pressure
Control (LPC) and Torque Converter Clutch (TCC) solenoids to prevent harsh shifts. The solenoid body tag
on the transaxle case contains the 13-digit solenoid body strategy and the 7-digit solenoid body identification.
Replacement Solenoid Body Tag
Item Description
Any time a new solenoid body is installed, a new solenoid body strategy file is downloaded into the PCM
using the scan tool. A replacement solenoid body tag is supplied with the new solenoid body which contains
the 13-digit solenoid body strategy and the 7-digit solenoid body identification. The new tag is placed over the
original solenoid body tag.
Solenoid Body Identification and Strategy
Original Solenoid Body Tag 3522

Item Description
If the solenoid body strategy printed on the solenoid body connector does not match the solenoid body tag, a
new solenoid body must be installed and the solenoid body strategy must be downloaded into the PCM or
harsh shifts will result.
Solenoid Band Number
The solenoids are calibrated from the factory and are not all the same. The solenoids can be replaced
separately, but only with a replacement solenoid with a band that matches the solenoid being replaced. When
solenoid(s) are replaced, the new solenoid band number must match the old solenoid band number. The band
number is the last digit of the number stamped on the side of the solenoid and will be a 1, 2, 3, 4 or 5.
Solenoid Body Identification and Strategy 3523

Solenoid Band Number 3524

Major Components
This transaxle has the following major components:
• Case with torque converter housing

• Two drive clutches:
♦ Direct clutch
♦ Overdrive (O/D) clutch
• Four brake clutches:
♦ Forward clutch
♦ Low one-way clutch
♦ Low/reverse clutch
♦ Intermediate clutch
• Three planetary gearsets:
♦ Front
♦ Center
♦ Rear
• Drive chain and sprockets
• Final drive planetary gearset and differential assembly
• Pump and filter assembly
• Main control:
♦ Valve body assembly
♦ Solenoid body assembly
Major Component Cutaway View
Major Components 3525

Major Component Exploded View

1 7G391 Solenoid body
2 7A100 Valve body
3 7B164 Forward clutch (clutch brake 1, 2, 3, 4)
4 7B164 Low/reverse clutch (clutch brake low/reverse)
5 7B164 Intermediate clutch (clutch brake 2, 6)
6 7A089 Low One-Way Clutch (OWC)
7 7B164 Direct clutch (drive clutch 3, 5, R)
8 7B164 Overdrive (O/D) clutch (drive clutch 4, 5, 6)
9 7D491 Rear planetary assembly
10 7D491 Center planetary assembly
11 7D491 Front planetary assembly
12 7F465 Final drive carrier and differential assembly
13 7G132 Drive chain driven sprocket
14 7G384 Input shaft assembly and direct/overdrive clutch hub
15 7A103 Pump assembly
16 7975 Torque converter
17 7G132 Drive chain drive sprocket
18 7G249 Drive chain
19 7060 Park gear
20 7A441 Park pawl
Major Component Exploded View 3526

Major Component Exploded View 3527

Gear Ratios
This transaxle has 6 forward speeds and reverse.
Gear Ratio Chart
Gear Ratio
1st/low 4.584:1
2nd 2.964:1
3rd 1.912:1
4th 1.446:1
5th 1:1
6th 0.746:1
Reverse 2.94:1
Gear Ratios 3528

Torque Converter
The torque converter transmits and multiplies torque. The torque converter is a 4-element device:
• Impeller and cover assembly

• Turbine
• Reactor
• Clutch and damper assembly
Rotation of the torque converter housing and impeller set the transmission fluid in motion by driving the
impeller blades and pump.
The turbine is driven by the transmission fluid from the impeller and transmits power to the input shaft.
The reactor redirects transmission fluid flow returned from the turbine to the impeller so that it rotates in the
same direction as the impeller. This action assists in torque multiplication.
The reactor has a One-Way Clutch (OWC) to hold it stationary during torque multiplication and allows it to
rotate at higher vehicle speeds.
Torque Converter Operation
Item Description
1 Torque Converter Clutch (TCC)
2 Reactor
3 Turbine
4 Impeller and cover assembly
5 One-Way Clutch (OWC)
6 Fluid motion
7 Input shaft rotation
8 Input shaft
9 Engine rotation

The Torque Converter Clutch (TCC) connects the torque converter housing to the damper when the TCC is
applied.
During TCC release, the direction that the transmission fluid flows through the torque converter allows the
TCC to release. During TCC apply, the transmission fluid flows in the opposite direction to apply the TCC .
The PCM controls TCC operation using the TCC solenoid in the solenoid body. TCC solenoid operation
provides the modulation of hydraulic pressure to change the position of the TCC control valve and TCC
regulator apply valve which changes the pressure and transmission fluid direction in the torque converter.
The TCC can be applied in 3rd, 4th, 5th and 6th gears.
Torque Converter Internal Component Exploded View
Item Description
1 Impeller and cover assembly
2 Torque Converter Clutch (TCC) and damper assembly
3 Turbine
4 Reactor
5 One-Way Clutch (OWC)
6 Thrust bearings
Torque Converter Operation 3530

Torque Converter Internal Component Exploded View 3531

Shift Patterns
Upshifts
Upshifting is controlled by the PCM. The PCM receives inputs from various engine or vehicle sensors and
driver demands to control shift scheduling, shift feel and Torque Converter Clutch (TCC) operation.
The PCM has an adaptive learn strategy to electronically control the transaxle which will automatically adjust
the shift feel through the life of the vehicle. The first few hundred miles of operation of the transaxle may
have abrupt shifting. This is a normal operation. To reset the adaptive shift pressure strategy, use the scan tool
to clear the transmission keep alive memory tables.
Downshifts
Under certain conditions, the transaxle will downshift automatically to a lower gear range (without moving
the selector lever). There are 3 categories of automatic downshifts: coastdown, torque demand and forced or
kickdown shifts.
Coastdown
The coastdown downshift occurs when the vehicle is ting down to a stop.
Torque Demand
The torque demand downshift occurs (automatically) during part throttle acceleration when the demand for
torque is greater than the engine can provide at that gear ratio. If applied, the transmission will disengage the
TCC to provide added acceleration.
Kickdown
For maximum acceleration, the driver can force a downshift by pressing the accelerator pedal to the floor. A
forced downshift into a lower gear is possible below calibrated speeds. Specifications for downshift speeds are
subject to variations due to tire size, engine and transaxle calibration requirements.
Shift Patterns 3532

Shift Patterns 3533

Mechanical Components and Functions
Planetary Gearset
This transaxle has 3 planetary gearsets to provide operation in reverse and 6 forward speeds.
The gearsets are comprised of the following components:
• Front planetary sun gear (part of the front sun gear and shell assembly)
• Front planetary carrier
• Front planetary ring gear
• Center planetary sun gear
• Center planetary carrier
• Center planetary ring gear
• Rear planetary ring gear
• Rear planetary carrier
• Rear planetary sun gear and shell assembly
The front planetary sun gear is splined to the forward (1, 2, 3, 4) clutch and is held stationary in 1st, 2nd, 3rd
and 4th gears.
The front planetary carrier is splined to the rear planetary ring gear and transfers power from the rear
planetary gearset to the front planetary gearset in 2nd, 3rd, 5th and 6th gears and reverse. The front planetary
carrier is splined to the drive chain drive sprocket. The front planetarrrier is the output component for the
planetary gearset.
The front planetary ring gear is splined to the center planetary carrier and transfers power from the center
planetary gearset to the front planetary gearset in 1st, 2nd, 3rd and 4th gears.
The center planetary sun gear is splined to the input shaft and is used as input to the planetary gearsets in 1st,
2nd, 3rd and 4th gear.
The center planetary ring gear is splined to the rear planetary carrier and transfers power from the center
planetary gearset to the rear planetary gearset in 3rd gear, from the rear planetary gearset to the center
planetary gearset in 4th gear and is held stationary by the low One-Way Clutch (OWC) and low/reverse clutch
in 1st gear and reverse.
The rear planetary carrier is splined to the Overdrive (O/D) (4, 5, 6) clutch hub and transfers power from the
input shaft to the rear planetary carrier in 4th, 5th and 6th gears.
The rear planetary sun gear and shell assembly is splined to both the intermediate (2, 6) clutch and the direct
(3, 5, R) clutch. The rear planetary sun gear and shell assembly is held stationary by the intermediate (2, 6)
clutch in 2nd and 6th gear and is driven by the direct (3, 5, R) clutch in 3rd and 5th gears and reverse.
Planetary Gearset Cutaway View
Mechanical Components and Functions 3534

Planetary Gearset Exploded View

1 7A019 Front planetary sun gear and shell assembly
2 7D491 Front planetary carrier/rear planetary ring gear
assembly
3 7D063 Gear - center planetary sun
4 7D491 Center planetary carrier/front ring gear assembly
5 7D491 Rear planetary carrier/center ring gear assembly
6 7A019 Rear planetary sun gear and shell assembly
Input Shaft
The input shaft is part of the direct/ O/D clutch assembly and is splined to the torque converter turbine and the
center planetary sun gear. The input shaft transfers power from the torque converter to the rear planetary
gearset through the center planetary sun gear and the direct (3, 5, R) and O/D (4, 5, 6) clutches.
Input Shaft Cutaway View
Planetary Gearset Cutaway View 3535

Input Shaft Exploded View

1 7G384 Direct (3, 5, R)/ Overdrive (O/D) (4, 5, 6) clutch hub
2 7F213 Input shaft
3 7B164 Direct (3, 5, R) clutch
4 7B164 O/D (4, 5, 6) clutch
5 7D491 Center planetary sun gear
Front Planetary Carrier Hub (Output Hub)
The front planetary carrier hub/park gear is splined to the front planetary carrier and the drive chain drive
sprocket. This allows torque to be transferred from the planetary gearset to the final drive gearset.
Front Planetary Carrier Hub Cutaway View
Input Shaft Cutaway View 3536

Front Planetary Carrier Hub Exploded View

1 7D491 Front planetary carrier
2 7060 Front planetary carrier hub/park gear
Final Drive Chain, Sprockets and Planetary Gearset
The final drive consists of a drive chain and sprockets and a planetary gearset and differential assembly. The
drive chain and sprockets transfer torque from the front planetary carrier hub to the differential assembly that
has a planetary gearset integrated into it for final drive torque multiplication.
The final drive consists of the following components:
• Drive sprocket
• Drive chain
• Driven sprocket
• Final drive sun gear
• Final drive ring gear
• Final drive planetary carrier and differential assembly
Front Planetary Carrier Hub Cutaway View 3537

Final Drive Component Cutaway View
Final Drive Component Exploded View

2 7G249 Drive chain
4 7F342 Final drive planetary sun gear
5 7F465 Differential assembly
6 7F343 Final drive planetary ring gear
7 7975 Torque converter housing
Differential
The differential allows the halfshafts and wheels to rotate at different speeds during cornering and transfers
power to the Power Transfer Unit (PTU) for All-Wheel Drive (AWD) vehicles.
The differential assembly consists of the following components:
• Differential case (part of the final drive carrier)
Final Drive Component Cutaway View 3538

• Two pinion gears supported by a pinion shaft
• Two side gears supported by the differential case and halfshafts
When driving in a straight line, both front wheels rotate at relatively the same speed. This means both side
gears are rotating at the same speed, as well, while both pinion gears revolve (but do not rotate) with the side
gears. During cornering, the wheel on the outside of the turn is forced to rotate faster than the wheel on the
inside of the turn. Since the side gears must now rotate at different speeds, the pinion gears rotate on the
pinion shaft allowing the drive axles to rotate at different speeds while still transferring output torque.
Differential Cutaway View
Differential Exploded View

1 7F465 Differential housing
2 - Pinion shaft
3 - Pinion gears
4 - Side gears
Direct (3, 5, R) Clutch
The direct clutch is a drive clutch that transfers power from the direct/ O/D clutch hub assembly to the rear
planetary sun gear and shell assembly. The direct clutch is applied in 3rd and 5th gears and reverse.
Hydraulic pressure from the regulator valve in the valve body pushes the direct clutch piston against the direct
clutch pack to apply the clutch. The input shaft and direct/ O/D clutch hub assembly transfers torque to the
rear planetary sun gear and shell assembly as a result of the clutch being applied.
Final Drive Component Exploded View 3539

Direct (3, 5, R) Clutch Cutaway View
Direct (3, 5, R) Clutch Exploded View

1 7C122 Direct clutch cylinder snap ring
2 7F283 Direct clutch cylinder
3 7A262 Direct clutch piston
4 7F235 Direct clutch piston return spring
5 7C099 Direct clutch piston seals
6 7G384 Direct/Overdrive (O/D) clutch hub
7 7F213 Input shaft
8 7B070 Direct clutch wave spring
9 7B164 Direct (3, 5, R) clutch assembly
10 7B066 Direct clutch pressure plate
11 7D483 Direct clutch snap ring
Overdrive (O/D) (4, 5, 6) Clutch
Direct (3, 5, R) Clutch Cutaway View 3540

The O/D clutch is a drive clutch that transfers power from the direct/ O/D clutch hub assembly to the rear
planetary carrier. The O/D clutch is applied in 4th, 5th and 6th gears.
Hydraulic pressure from the regulator valve in the valve body pushes the O/D clutch piston against the O/D
clutch pack to apply the clutch. The input shaft and direct/ O/D clutch hub assembly transfers torque to the
rear planetary carrier as a result of the clutch being applied.
Overdrive (O/D) (4, 5, 6) Clutch Cutaway View
Overdrive (O/D) (4, 5, 6) Clutch Exploded View

1 7G384 Direct/Overdrive (O/D) clutch hub assembly
2 7A548 O/D clutch piston inner seal
3 7F213 Input shaft
4 7A548 O/D clutch piston outer seals
5 7A262 O/D clutch piston
6 7F222 O/D clutch piston return spring
7 7H360 O/D clutch balance piston
8 7C122 O/D clutch balance piston snap ring
Direct (3, 5, R) Clutch Exploded View 3541

9 7B164 O/D (4, 5, 6) clutch assembly

10 7B066 O/D clutch pressure plate
11 7D483 O/D clutch snap ring
12 7H351 O/D clutch hub
13 7D491 Rear planetary carrier
Forward (1, 2, 3, 4) Clutch
The forward clutch is a brake clutch that holds the front sun gear and shell assembly. The forward clutch is
applied in 1st, 2nd, 3rd and 4th gears.
Hydraulic pressure from the regulator valve in the valve body pushes the forward clutch piston against the
forward clutch pack to apply the clutch. The front sun gear and shell assembly is held stationary to the
transaxle case as a result of the clutch being applied.
Forward (1, 2, 3, 4) Clutch Cutaway View
Forward (1, 2, 3, 4) Clutch Exploded View

1 7005 Transaxle case
Overdrive (O/D) (4, 5, 6) Clutch Exploded View 3542

2 7L328 Center support

3 7A262 Forward clutch piston
4 7B070 Forward clutch piston return spring
5 7H365 Forward clutch piston return spring snap ring
6 7B070 Forward clutch wave spring
7 7B164 Forward (1, 2, 3, 4) clutch
8 7B066 Forward clutch pressure plate
9 7D483 Forward clutch snap ring
10 7A019 Front sun gear and shell assembly
Low/Reverse Clutch
The low/reverse clutch is a brake clutch that holds the low OWC which is splined to the rear planetary carrier.
The low/reverse clutch is applied in manual LOW, REVERSE and 1st gear up to 8 km/h (5 mph).
Hydraulic pressure from the regulator valve in the valve body pushes the low/reverse clutch piston against the
low/reverse clutch pack to apply the clutch. The rear planetary carrier is held stationary to the transaxle case
as a result of the clutch being applied.
Low/Reverse Clutch Cutaway View
Low/Reverse Clutch Exploded View
Forward (1, 2, 3, 4) Clutch Exploded View 3543


4 7B066 Low/reverse clutch pressure plate
5 7B164 Low/reverse clutch
6 7E085 Low/reverse clutch wave spring
7 7C122 Low/reverse clutch piston return spring snap ring
8 7B070 Low/reverse clutch piston return spring
9 7D402 Low/reverse clutch piston
Intermediate (2, 6) Clutch
The intermediate clutch is a brake clutch that holds the rear planetary sun gear and shell assembly. The
intermediate clutch is applied in 2nd and 6th gears.
Hydraulic pressure from the regulator valve in the valve body pushes the intermediate clutch piston against
the intermediate clutch pack to apply the clutch. The low OWC works as a pressure plate for the intermediate
(2, 6) clutch. The rear planetary sun gear and shell assembly is held stationary to the transaxle case as a result
of the clutch being applied.
Intermediate (2, 6) Clutch Cutaway View
Low/Reverse Clutch Exploded View 3544

Intermediate (2, 6) Clutch Exploded View

2 7E005 Intermediate clutch piston
3 7B070 Intermediate clutch piston return spring
4 7D483 Intermediate clutch piston return spring snap ring
5 7E005 Intermediate clutch apply ring
7 7E085 Intermediate clutch wave spring
8 7B164 Intermediate clutch assembly
9 7A089 Low/One-Way Clutch (OWC)
Low One-Way Clutch (OWC)
The low OWC is a brake clutch that holds the rear planetary carrier in one direction and allows it to freewheel
in the opposite direction which eliminates engine braking in 1st gear when the transaxle is in DRIVE. The low
OWC is also the pressure plate for the intermediate (2, 6) clutch.
Intermediate (2, 6) Clutch Cutaway View 3545

Low One-Way Clutch (OWC) Cutaway View
Low One-Way Clutch (OWC) Exploded View

External Sealing
The torque converter housing has a lip-type seal that seals the torque converter hub. The pump assembly seals
to the torque converter housing with a rubber seal. The manual shaft and halfshafts also use lip-type seals.
All-Wheel Drive (AWD) vehicles do not use a RH halfshaft seal, the transaxle is sealed by the Power Transfer
Unit (PTU) on the RH side.
The torque converter housing is sealed to the transaxle case with silicone sealant.
The main control cover is sealed to the transaxle case with silicone sealant and seals to the solenoid body with
a reusable rubber gasket. The Turbine Shaft Speed (TSS) sensor is sealed to the transaxle case with an O-ring
seal.
The line pressure tap plug and transmission fluid drain plug have pipe threads and seal when tightened to
specification.
Low One-Way Clutch (OWC) Cutaway View 3546

The transmission fluid filler tube is sealed to the torque converter housing with an O-ring seal.
External Sealing Exploded View

2 7A248 Torque converter hub seal
5 7A248 Pump assembly-to-torque converter housing O-ring
seal
6 7F337 Manual control shaft seal
7 1177 RH halfshaft seal
8 1177 LH halfshaft seal
10 7M101 Turbine Shaft Speed (TSS) sensor
11 - TSS sensor O-ring seal
12 7G004 Main control cover
13 7B329 Main control-to-cover seal
14 7H398 Line pressure tap plug
15 7010 Drain plug
16 7A228 Transmission fluid filler tube
17 391308 Transmission fluid filler tube O-ring seal
Bearing and Thrust Washer Locations
Low One-Way Clutch (OWC) Exploded View 3547


1 7F242 No. 1 thrust bearing
2 7D234 No. 2 thrust bearing
4 7G177 No. 5 thrust bearing
5 7C096 No. 6 thrust bearing
7 7C096 . 8 thrust bearing
11 7G099 No. 13 thrust washer
The No. 4 thrust bearing is part of the rear planetary carrier assembly. The No. 9 thrust bearing is part of the
front planetary carrier assembly. The No. 14 thrust bearing is part of the differential assembly.
Lubrication
Transmission fluid enters the lubrication circuits after flowing through the transmission fluid cooler. The
transmission fluid cooler is mounted at the front of the vehicle. When the transmission fluid is not up to
operating temperature, an internal thermal bypass valve allows the transmission fluid to bypass the
transmission fluid cooler. When the transmission fluid circulates through the transmission fluid cooler, the
transmission fluid returns to the transaxle from the transmission fluid cooler tubes through the back
transmission fluid cooler tube.
The transmission fluid enters main lubrication circuit through the transaxle case and flows through passages in
the input shaft to lubricate the transaxle.
External Sealing Exploded View 3548

The transmission fluid in the input shaft circuit flows from the back of the input shaft toward the front of the
input shaft and passes through ports in the input shaft to lubricate the planetary gearset, clutches, final drive
assembly and other components of the transaxle.

1 7D273 Transmission fluid cooler return tube fitting
2 7H322 Thermal bypass valve assembly
Lubrication Passages
Park
The park gear is splined to the front planetary carrier and the drive chain drive sprocket. There are lugs around
the outer diameter of the park gear to allow the park pawl to hold the park gear stationary to the transaxle case
which holds the final drive assembly in place and keeps the vehicle from moving.
Lubrication Passages 3549

When the manual control lever is rotated to the PARK position, the park lock works as follows:
• The Transmission Range (TR) sensor rotates the range detent plate which pushes the park pawl
actuator rod towards the park pawl.
• The actuator rod pivots the park pawl into the lugs on the park gear, locking the gear stationary to the
transaxle case.
Park Component Exploded View

1 W714437 Transmission Range (TR) sensor detent spring bolt
2 7E332 TR sensor detent spring
3 7G100 Manual shaft-to- TR sensor pin
4 7A232 Park pawl actuator rod
5 7H557 TR sensor
6 7C493 Manual shaft
7 7A256 Manual lever
8 7F337 Manual shaft seal
9 W302864 Manual lever nut
10 7A441 Park pawl
11 7D071 Park pawl pin
12 7D070 Park pawl spring
14 7090 Park gear
16 7C122 Drive sprocket snap ring
Park Component Exploded View 3550

20 7F342 Final drive planetary gearset sun gear

21 7F465 Final drive planetary carrier/differential assembly
22 7C122 Final drive planetary ring gear snap ring
23 7F343 Final drive planetary ring gear
Park Component Exploded View 3551

Hydraulic System
Transmission Fluid Filter
The transmission fluid in the sump area at the bottom of the transaxle case flows through a transmission fluid
filter to the pump assembly. The pump is bolted to the torque converter housing and is driven by the torque
converter hub.
Fluid Pump and Transmission Fluid Filter Components

3 7A098 Transmission fluid filter
4
5 W302860 Pump-to-torque converter housing bolt
Transmission Fluid Level
The transmission fluid level is checked with the transaxle at normal operating temperature between 85°C and
93°C (185°F and 200°F).
The transmission fluid level indicator is part of the transmission fluid filler tube located at the back of the
torque converter housing.
The correct transmission fluid level is between the minimum and maximum marks on the transmission fluid
level indicator.
Transmission Fluid Level Indicator
Hydraulic System 3552

Part
Item Number Description
1 7A020 Transmission fluid level indicator
2 7A228 Transaxle filler tube
3 - Correct transmission fluid level at normal operating
temperature 85°C-93°C (185°F-200°F)
4 - Minimum transmission fluid level mark
5 - Maximum transmission fluid level mark
6 - Flat tow transmission fluid level
Main Control
The hydraulic system has a main contromain control assembly consists of a valve body and a solenoid body.
Both the valve body and the solenoid body contain hydraulic shift valves. The solenoid body contains the shift
solenoids that control the hydraulic valves. The solenoid body can be serviced as an assembly with the
solenoids or the solenoids can be serviced individually. The solenoid body is controlled by the PCM. The
PCM has software stored in it specific to the solenoid body currently in the transaxle, called the solenoid body
strategy. A new solenoid body strategy must be downloaded into the PCM anytime a new solenoid body is
installed.
The pump assembly contains the main pressure regulator valve assembly and the Torque Converter Clutch
(TCC) control valve assembly.
Main Control Components
Transmission Fluid Level Indicator 3553


4 7Z490 Main control-to-transaxle case separator plate
5 7A100 Valve body
6 7E195 Check balls
7 7J191 Solenoid damper (Shift Solenoid A (SSA))
8 7G391 Solenoid body assembly
Main Control Valve Body

1 7C389 Manual valve
2 7G473 Solenoid pressure regulator valve assembly
3 7G179 Clutch bypass valve
4 7G307 Torque Converter Clutch (TCC) regulator valve
5 7B200 Control pressure regulator
6 7D102 Direct (3, 5, R) clutch regulator valve
Main Control Components 3554

7 7D102 Intermediate (2, 6) clutch regulator valve

8 7D102 Forward (1, 2, 3, 4) clutch regulator valve
9 7J187 Forward (1, 2, 3, 4) clutch latch valve
10 7D102 Low reverse/overdrive (4, 5, 6) clutch regulator valve
11 7A100 Valve body
Solenoid Body

1 7Z490 Main control valve body-to-solenoid body separator
plate
3 7G276 Solenoid body leadframe
4 7J187 Direct (3, 5, R) clutch latch valve
5 7J187 Intermediate (2, 6) clutch latch valve
6 7J187 Low reverse/overdrive (4, 5, 6) clutch latch valve
7 7G383 Line Pressure Control (LPC) solenoid
8 7G136 Shift Solenoid C (SSC)
9 7G136 Torque Converter Clutch (TCC)
10 7G484 ON/OFF solenoid
11 7G136 Shift Solenoid A (SSA)
12 7G383 Shift Solenoid B (SSB)
13 7G383 Shift Solenoid D (SSD)
Main Control Valve Body 3555

Pump Assembly

2 - Main pressure regulator valve assembly
3 - Torque Converter Clutch (TCC) control valve
assembly
Pump Assembly 3556

Hydraulic Circuits
Hydraulic Circuit Identification and Function
Hydraulic Circuit Identification Chart
Circuit Name Description

BYPASS Pressure from the main pressure regulator valve to the pump assembly suction circuit for line
pressure control.
C1234 Regulated line pressure from the 1234 regulator valve supplied to the forward (1, 2, 3, 4)
clutch to apply the clutch.
C1234 FDBK C1234 pressure from the 1234 latch valve supplied to the 1234 regulator valve to oppose
movement of the valve from VBS C1234 pressure during forward (1, 2, 3, 4) clutch
application.
C35R Regulated line pressure from the 35R regulator valve supplied to the direct (3, 5, R) clutch to
apply the clutch.
C35R FD Line pressure from the REVERSE circuit supplied to the DRIVE 2/C35R FD shuttle valve by
the clutch control bypass valve to supply the 35R regulator valve with line pressure in
reverse.
C35R FDBK C35R pressure from the 35R latch valve supplied to the 35R regulator valve to oppose
movement of the valve from VBS C35R pressure during direct (3, 5, R) clutch application.
C456 Regulated line pressure from the low reverse/456 regulator valve directed to the Overdrive
(O/D) (4, 5, 6) clutch by the clutch control bypass valve. C456 also provides latch pressure
for the clutch control bypass valve.
CB26 Regulated line pressure from the 26 regulator valve to the intermediate (2, 6) clutch to apply
the clutch in 2nd and 6th gears.
CB26 FDBK CB26 pressure from the 26 latch valve supplied to the 26 regulator valve to oppose
movement of the valve from VBS C26 pressure during intermediate (2, 6) clutch application.
CBR1 Regulated line pressure from the low reverse/456 regulator valve directed to the low/reverse
clutch by the clutch control bypass valve.
CBR1/C456
Hydraulic Circuits 3557

Regulated line pressure from the low reverse/456 regulator valve to the clutch control bypass
valve.
CBR1/C456 CBR1/C456 pressure from the low reverse/456 latch valve supplied to the low reverse/456
FDBK regulator valve to oppose movement of the valve from VBS CBR1/456 pressure during
low/reverse or O/D (4, 5, 6) clutch application.
COMP FD Pressure supplied to the opposite side of the O/D (4, 5, 6) and direct (3, 5, R) clutch apply
pistons to oppose centrifugal application of the clutches.
CONV FD Line pressure from the main pressure regulator valve supplied to the Torque Converter
Clutch (TCC) control valve for TCC release.
COOLER FD Return pressure from the torque converter during TCC release that is directed to the
transmission fluid cooler by the TCC control valve.
DRIVE Line pressure directed to the clutch control bypass valve, 1234 regulator valve and the 26
regulator valve by the manual valve in the DRIVE position.
DRIVE 2 DRIVE pressure directed to the TCC regulator valve and the DRIVE 2/C35R FD shuttle
valve by the clutch control bypass valve to supply the 35R regulator valve with line pressure
in 3rd and 5th gears.
DRIVE DRIVE 2 or C35R FD pressure supplied to the 35R regulator valve from the DRIVE 2/C35R
2/C35R FD FD shuttle valve during direct (3, 5, R) clutch application.
EXH Fluid exhausted from the valves that drains to the sump area.
EXH BF Unpressurized fluid from the manual valve that fills the unused hydraulic circuits.
LINE Pressure from the pump to the control pressure regulator, solenoid regulator valve, manual
valve and low reverse/456 regulator valve. Line pressure is regulated by the main pressure
regulator valve.
LUBE Transaxle lubrication circuit (through the input shaft)
ON/OFF SIG Full solenoid output pressure from Shift Solenoid E (SSE) to the clutch control bypass valve
and the TCC regulator valve. ON/OFF SIG pressure positions the clutch control bypass valve
to apply either the low/reverse clutch or the O/D (4, 5, 6) clutch.
REG APPLY Regulated DRIVE 2 pressure supplied to the TCC control valve by the control pressure
regulator for TCC application.
REVERSE Line pressure directed to the clutch control bypass valve by the manual valve in the
REVERSE position.
SOL FD Regulated line pressure supplied to the shift, TCC and Line Pressure Control (LPC)
solenoids.
TCC APPLY Pressure supplied to the torque converter by the TCC control valve to apply the clutch. TCC
APPLY is also the return circuit for the TCC RELEASE circuit.
TCC Pressure supplied to the torque converter by the TCC control valve to release the clutch. TCC
RELEASE RELEASE is also the return circuit for the TCC APPLY circuit.
VBS C1234 Variable SOL FD pressure supplied to the 1234 regulator valve and 1234 latch valve by Shift
Solenoid A (SSA) to position the valves to apply the forward (1, 2, 3, 4) clutch.
VBS C35R Variable SOL FD pressure supplied to the 35R regulator valve and 35R latch valve by Shift
Solenoid B (SSB) to position the valves to apply the direct (3, 5, R) clutch.
VBS CB26 Variable SOL FD pressure supplied to the 26 regulator valve and 26 latch valve by Shift
Solenoid C (SSC) to position the valves to apply the intermediate (2, 6) clutch.
VBS Variable SOL FD pressure supplied to the low reverse/456 regulator valve and low
CBR1/456 reverse/456 latch valve by Shift Solenoid D (SSD) to position the valves to apply the
low/reverse clutch or O/D (4, 5, 6) clutch.
VBS LINE Variable SOL FD pressure supplied to the main pressure regulator valve by the LPC solenoid
to control line pressure.
VBS TCC

Variable SOL FD pressure supplied to the TCC regulator valve and TCC control valve to
position the valves by the TCC solenoid to apply the TCC .


Line Pressure Hydraulic Circuits
Line pressure is controlled by the Line Pressure Control (LPC) solenoid, which is controlled by the PCM.
This effects shift feel and apply component operation.
When the engine is running, the pump supplies pressure to the main pressure regulator valve, which is
controlled by the LPC solenoid. The main pressure regulator valve controls the line pressure to the LINE
circuit which supplies the manual valve solenoid regulator valve and the control pressure regulator valve.
When the manual valve is in the reverse position, it supplies the clutch control bypass valve with line pressure
to position it to supply line pressure to the direct (3, 5, R) regulator valve and regulated line pressure to the
low/reverse clutch to apply the clutch.

When the manual valve is in the DRIVE or LOW positions, it directs line pressure from the LINE circuit to
the DRIVE circuit to supply line pressure to the:
• Clutch control bypass valve

• Forward (1, 2, 3, 4) regulator valve
• Intermediate (2, 6) regulator valve
• Torque Converter Clutch (TCC) regulator valve
• Direct (3, 5, R) clutch regulator valve
Torque Converter Clutch (TCC) And Lubrication Hydraulic Circuits
Pressure for TCC release is supplied by the main pressure regulator valve to the TCC control valve through
the CONV FD circuit. The CONV FD circuit also supplies lubrication for the differential. When the TCC is
released, the TCC control valve is positioned by the TCC solenoid to direct CONV FD pressure to the TCC
RELEASE circuit to release the TCC . TCC RELEASE pressure returns to the TCC control valve through the
TCC APPLY circuit. The position of the TCC control valve opens the TCC APPLY circuit to the COOLER
FD circuit which allows the transmission fluid returned from the torque converter to cycle through the thermal
bypass valve circuit when the Transmission Fluid Temperature (TFT) is below 80°C-93°C (176°F-200°F) or
the transmission fluid cooler when the temperature is above 80°C-93°C (176°F-200°F).
Return transmission fluid from tal bypass valve or the transmission fluid cooler supplies transaxle lubrication
through the LUBE circuit which runs through the input shaft.
For lubrication passage location and description, refer to Mechanical Components and Functions in this
section.
The position of the TCC control valve is controlled by pressure from the TCC solenoid through the VBS TCC
circuit. The TCC solenoid is controlled by the PCM.

When the TCC clutch is applied, the TCC solenoid applies pressure to the TCC control and regulator valves to
position the valves to apply the TCC clutch. Regulated line pressure is supplied to the TCC control valve
through the REG APPLY circuit by the TCC regulator valve. The TCC control valve directs the regulated line
pressure from the REG APPLY circuit to the TCC APPLY circuit to apply the TCC . The TCC control valve
blocks the TCC RELEASE circuit to maintain pressure in the TCC APPLY circuit. The TCC control valve
directs the CONV FD circuit to the COOLER FD circuit to allow the transmission fluid to flow through the
thermal bypass valve or the transmission fluid cooler to the LUBE circuit to lubricate the transaxle.
Solenoid Hydraulic Circuits
Line pressure from the main pressure regulator valve is directed to the individual shift, TCC and LPC
solenoids by the solenoid regulator valve through the SOL FD circuit. The solenoids, controlled by the PCM,
direct the fluid to the valves that they control.
The LPC solenoid applies varying pressure to the main pressure regulator valve to control line pressure.
In the PARK and NEUTRAL positions, Shift Solenoid D (SSD) applies varying pressure to the low
reverse/456 regulator and latch valves through the VBS CBR1/456 hydraulic circuit to position the valves to
apply the low/reverse clutch. ON/OFF Shift Solenoid E (SSE) directs pressure to the clutch control bypass
valve to position the valve to direct regulated line pressure from the low reverse/456 regulator valve to the
low/reverse clutch.

In the REVERSE position, SSD applies varying pressure to the low reverse/456 regulator and latch valves
through the VBS CBR1/456 hydraulic circuit to position the valves to apply the low/reverse clutch. ON/OFF
SSE directs pressure to the clutch control bypass valve to position the valve to direct regulated line pressure
from the low reverse/456 regulator valve to the low/reverse clutch. The clutch control bypass valve also
directs line pressure from the REVERSE circuit to the 35R regulator valve through the C35R FD and DRIVE
2/C35R FD circuits. Shift Solenoid B (SSB) directs varying pressure to the 35R regulator and latch valves
through the VBS C35R hydraulic circuit to apply the direct (3, 5, R) clutch.
In 1st gear, Shift Solenoid A (SSA) applies varying pressure to the 1234 clutch regulator and latch valves
through the VBS C1234 hydraulic circuit to apply the forward (1, 2, 3, 4) clutch.
When vehicle speed is below 8 km/h (5 mph), or the selector lever is in the manual low position, SSD applies
varying pressure to the low reverse/456 regulator and latch valves through the VBS CBR1/456 hydraulic
circuit to position the valves to apply the low/reverse clutch. ON/OFF SSE directs pressure to the clutch
control bypass valve to position the valve to direct regulated line pressure from the low reverse/456 regulator
valve to the low/reverse clutch. As vehicle speed increases above 8 km/h (5 mph) in 1st gear, SSD removes
pressure from the low reverse/456 regulator and latch valves and SSE removes pressure from the clutch
control bypass valve to release the low/reverse clutch.

In 2nd gear, the forward (1, 2, 3, 4) clutch remains applied. SSC applies varying pressure to the 26 regulator
and latch valves through the VBS CB26 hydraulic circuit to apply the intermediate (2, 6) clutch.
In 3rd gear, the forward (1, 2, 3, 4) clutch remains applied. SSC releases pressure to the 26 regulator and latch
valves to release the intermediate (2, 6) clutch. SSB directs pressure to the 35R regulator and latch valves
through the VBS CB26 hydraulic circuit to apply the direct (3, 5, R) clutch.

In 4th gear, the forward (1, 2, 3, 4) clutch remains applied. SSB releases pressure to the 35R regulator and
latch valves. SSD directs pressure to the low reverse/456 regulator and latch valves through the VBS
CBR1/456 hydraulic circuit. With SSE released, the clutch control bypass valve directs the regulated line
pressure from the low reverse/456 regulator valve to the Overdrive (O/D) (4, 5, 6) clutch to apply the clutch.
In 5th gear, the O/D (4, 5, 6) clutch remains applied. SSA releases pressure to the 1234 regulator and latch
valves to release the forward (1, 2, 3, 4) clutch. SSB directs pressure to the 35R regulator and latch valves
through the VBS C35R hydraulic circuit to apply the direct (3, 5, R) clutch.
In 6th gear, the O/D (4, 5, 6) clutch remains applied. SSB releases pressure to the 35R regulator and latch
valves. SSC applies varying pressure to the 26 clutch regulator and latch valves through the VBS CB26
hydraulic circuit to apply the intermediate (2, 6) clutch.

The TCC can be applied in 4th, 5th or 6th gear. To apply the TCC , the TCC solenoid applies pressure to the
TCC regulator valve and the TCC control valve to position the valves to apply the clutch.
During a mechanical, hydraulic or electrical failure with the manual lever in the DRIVE position, the transaxle
defaults to 5th gear. When the transaxle is in 5th gear failsafe, the PCM does not control the shift solenoids
and they default to their normal state (maximum pressure, minimum pressure, on or off). The LPC solenoid
defaults to maximum pressure, SSA defaults to minimum pressure, SSB defaults to maximum pressure, SSC
defaults to minimum pressure, SSD defaults to maximum pressure and the TCC solenoid defaults to minimum
pressure.
With SSB applying maximum pressure to the direct (3, 5, R) regulator and latch valves, the direct (3, 5, R)
clutch is applied. With SSD applying maximum pressure to the low reverse/456 regulator and latch valves
with SSE in the OFF position, the O/D (4, 5, 6) clutch is applied, providing 5th gear.
Forward (1, 2, 3, 4) Clutch Hydraulic Circuits
Line pressure is supplied to the 1234 regulator valve by the manual valve in the DRIVE and LOW position.
To apply the forward (1, 2, 3, 4) clutch, SSA supplies varying solenoid pressure to the 1234 regulator and
latch valves. As the regulator valve moves, it supplies the forward (1, 2, 3, 4) clutch and 1234 latch valve with
regulated line pressure through the C1234 circuit. The 1234 latch valve directs the regulated line pressure to
the opposite side of the 1234 regulator valve through the C1234 FDBK circuit for gradual forward (1, 2, 3, 4)
clutch engagement. The forward (1, 2, 3, 4) clutch is applied in 1st, 2nd, 3rd and 4th gears and manual LOW
position.

When the forward (1, 2, 3, 4) clutch is released in 5th and 6th gears, solenoid pressure from SSA is removed
from the 1234 regulator and latch valves which positions the valves to block line pressure and release the
forward (1, 2, 3, 4) clutch. When the forward (1, 2, 3, 4) clutch is released in the PARK, REVERSE or
NEUTRAL position, line pressure is not supplied to the forward (1, 2, 3, 4) regulator valve.
In the released position, exhaust backfill supplied to the 1234 regulator and latch valves by the manual valve
through the EXH BF circuit is directed to the forward (1, 2, 3, 4) clutch to fill the unused circuits with
unpressurized transmission fluid.
Direct (3, 5, R) Clutch Hydraulic Circuits
When the direct (3, 5, R) clutch is applied in the REVERSE position, line pressure from the manual valve is
directed to the clutch control bypass valve through the REVERSE circuit. Line pressure in the REVERSE
circuit positions the clutch control bypass valve and supplies line pressure to apply the direct (3, 5, R) clutch.
Line pressure from the clutch control bypass valve is supplied to the 35R regulator valve through the C35R
FD circuit, DRIVE 2/C35R FD shuttle ball and DRIVE 2/C35R FD circuit.
To apply the direct (3, 5, R) clutch, SSB applies varying solenoid pressure to the 35R regulator and latch
valves. As the regulator valve moves, it supplies the direct (3, 5, R) clutch and 35R latch valve with regulated
line pressure through the C35R circuit. The 35R latch valve directs the regulated line pressure to the opposite
side of the 35R regulator valve through the C35R FDBK circuit for gradual direct (3, 5, R) clutch
engagement.

When the direct (3, 5, R) clutch is applied in 3rd and 5th gear, line pressure from the pump is directed to the
clutch control bypass valve by the manual valve through the DRIVE hydraulic circuit. The clutch control
bypass valve directs the pressure to the 35R regulator valve through the TCC regulator valve, DRIVE 2
circuit, DRIVE 2/C35R FD shuttle ball and DRIVE 2/C35R FD circuit.
To apply the direct (3, 5, R) clutch, SSB applies varying solenoid pressure to the 35R regulator and latch
valves. As the 35R regulator valve moves, it supplies the direct (3, 5, R) clutch and 35R latch valve with
regulated line pressure through the C35R circuit. The 35R latch valve directs the regulated line pressure to the
opposite side of the regulator valve through the C35R FDBK circuit for gradual direct (3, 5, R) clutch
engagement.
When the direct (3, 5, R) clutch is released, solenoid pressure from SSB is removed from the 35R regulator

and latch valves which positions the valves to block line pressure and release the direct (3, 5, R) clutch. When
the direct (3, 5, R) clutch is released in the PARK or NEUTRAL position, line pressure is not supplied to the
35R regulator valve.
Compensator feed pressure is supplied to the 35R regulator valve from the control pressure regulator through
the COMP FD circuit and is supplied to the opposite side of the direct (3, 5, R) and O/D (4, 5, 6) clutch
pistons to keep the clutches from centrifugally applying. COMP FD pressure is only about 83 kPa (12 psi) and
is applied through all gears. When the direct (3, 5, R) clutch is released, COMP FD is applied by the 35R
regulator valve to the direct (3, 5, R) clutch to fill the unused circuits.
Intermediate (2, 6) Clutch Hydraulic Circuits
Line pressure is supplied to the 26 regulator valve by the manual valve in the DRIVE and LOW positions. To
apply the intermediate (2, 6) clutch, SSC supplies varying solenoid pressure to the 26 regulator and latch
valves. As the 26 regulator valve moves, it supplies the intermediate (2, 6) clutch and 26 latch valve with
regulated line pressure through the CB26 circuit. The 26 latch valve directs the regulated line pressure to the
opposite side of the 26 regulator valve through the CB26 FDBK circuit for gradual intermediate (2, 6) clutch
engagement. The intermediate (2, 6) clutch is applied in 2nd and 6th gears.

When the intermediate (2, 6) clutch is released in 1st, 3rd, 4th and 5th gears and manual LOW position,
solenoid pressure from SSC is removed from the 26 regulator and latch valves which positions the valves to
block line pressure and release the intermediate (2, 6) clutch. When the intermediate (2, 6) clutch is released
in the PARK, REVERSE or NEUTRAL position, line pressure is not supplied to the 26 regulator valve.
In the released position, exhaust backfill supplied to the 26 clutch regulator valve by the manual valve through
the EXH BF circuit is directed to the intermediate (2, 6) clutch and 26 latch valve to fill the unused circuits
with unpressurized transmission fluid.
Low/Reverse Clutch Hydraulic Circuits
Line pressure is supplied to the low reverse/456 regulator valve by the pump in every gear and manual lever
position. To apply the low/reverse clutch, SSD supplies varying solenoid pressure to the low reverse/456
regulator and latch valves. As the low reverse/456 regulator valve moves, it supplies the clutch control bypass
valve and low reverse/456 latch valve with regulated line pressure through the CBR1/C456 circuit. The low
reverse/456 latch valve directs the regulated line pressure to the opposite side of the 456 regulator valve
through the CBR1/C456 FDBK circuit for gradual low reverse/456 clutch engagement. The low/reverse clutch
is applied in PARK, REVERSE, NEUTRAL, 1st gear below 8 km/h (5 mph) and manual LOW position.
In REVERSE, both solenoid pressure from ON/OFF SSE and line pressure from the manual valve in the
REVERSE circuit apply pressure to the clutch control bypass valve to position it for low/reverse clutch
application. Regulated line pressure from the CBR1/C456 circuit is directed to the low/reverse clutch by the
clutch control bypass valve through the CBR1 circuit to apply the low/reverse clutch.

When the low/reverse clutch is applied in PARK, NEUTRAL, LOW or 1st gear below 8 km/h (5 mph), only
pressure from ON/OFF SSE , positions the clutch control bypass valve. Line pressure from the REVERSE
circuit is not supplied by the manual valve.
When the low/reverse clutch is released in 1st gear above 8 km/h (5 mph), 2nd and 3rd gears, solenoid
pressure from SSD is removed from the low reverse/456 regulator and latch valves which positions the valves
to block line pressure and release the low/reverse clutch. Solenoid pressure from SSE is removed from the
clutch control bypass valve to position it to apply the O/D (4, 5, 6) clutch.
When the low/reverse clutch is released in 1st gear above 8 km/h (5 mph), 2nd and 3rd gears, exhaust backfill
supplied to the low reverse/456 clutch regulator valve and the clutch control bypass valve by the manual valve
through the EXH BF circuit is directed to the low reverse/456 latch valve, low/reverse clutch and O/D (4, 5, 6)
clutch to fill the unused circuits with unpressurized transmission fluid.
When the low/reverse clutch is released in 4th, 5th and 6th gears, the low reverse/456 regulator valve supplies
regulated pressure to the clutch control bypass valve through the CBR1/C456 circuit. With ON/OFF SSE in
the OFF position, the regulated pressure is directed to the O/D (4, 5, 6) clutch.

Overdrive (4, 5, 6) Clutch Hydraulic Circuits
Line pressure is supplied to the low reverse/456 regulator valve by the pump in every gear and manual lever
position. To apply the low/reverse clutch, SSD supplies varying solenoid pressure to the low reverse/456
regulator and latch valves. As the regulator valve moves, it supplies the clutch control bypass valve and low
reverse/456 latch valve with regulated line pressure through the CBR1/C456 circuit. The low reverse/456
latch valve directs the regulated line pressure to the opposite side of the low reverse/456 regulator valve
through the CBR1/C456 FDBK circuit for gradual O/D (4, 5, 6) clutch engagement.
To apply the O/D (4, 5, 6) clutch, the position of the clutch control bypass valve allows the regulated line
pressure in the CBR1/C456 circuit to supply the C456 circuit, applying the O/D (4, 5, 6) clutch. Clutch
control bypass valve latch pressure is supplied by the C456 circuit. The O/D (4, 5, 6) clutch is applied in 4th,
5th and 6th gears.
When the O/D (4, 5, 6) clutch is released in 1st gear above 8 km/h (5 mph), 2nd and 3rd gears, solenoid
pressure from SSD is removed from the low reverse/456 regulator and latch valves which positions the valves
to block line pressure and release the O/D (4, 5, 6) clutch.

When the O/D (4, 5, 6) clutch is released in 1st gear above 8 km/h (5 mph), 2nd and 3rd gears, exhaust
backfill supplied to the low reverse/456 clutch regulator valve and the clutch control bypass valve by the
manual valve through the EXH BF circuit is directed to the low reverses latch valve, low/reverse clutch and
O/D (4, 5, 6) clutch to fill the unused circuits with unpressurized transmission fluid.
When the O/D (4, 5, 6) clutch is released in PARK, REVERSE, NEUTRAL and 1st gear below 8 km/h (5
mph), the low reverse/456 regulator valve supplies regulated pressure to the clutch control bypass valve
through the CBR1/C456 circuit. With ON/OFF SSE in the ON position, the regulated pressure is directed to
the low/reverse clutch.

Transaxle Electronic Control System
Electronic System Description
The PCM and its input/output network control the following operations:
• Shift timing
• Line pressure (shift feel)
• Torque Converter Clutch (TCC)
The transaxle control is separate from the engine control strategy in the PCM, although some of the input
signals are shared. When determining the best operating strategy for transaxle operation, the PCM uses input
information from certain engine-related and driver-demand related sensors and switches.
In addition, the PCM receives input signals from certain transaxle-related sensors and switches. The PCM also
uses these signals when determining transaxle operating strategy.
Using all of these input signals, the PCM can determine when the time and conditions are right for a shift, or
when to apply or release the TCC . It will also determine the best line pressure needed to optimihift
engagement feel. To accomplish this, the PCM uses output solenoids to control transaxle operation.
The following provides a brief description of each of the sensors and actuators used to control transaxle
operation.
Electronic Ignition (EI)
The Electronic Ignition (EI) system consists of the PCM, a Crankshaft Position (CKP) sensor and ignition
coils. The CKP sensor sends a crankshaft position signal to the PCM. The PCM then sends the appropriate
ignition signal to the ignition coils. The PCM also uses this signal as well as Wide Open Throttle (WOT) shift
control, TCC control and electronic pressure control.
Accelerator Pedal Position (APP)
The Accelerator Pedal Position (APP) sensor is mounted on the accelerator pedal. The APP detects the
position of the accelerator pedal and inputs this information as a voltage to the PCM. The PCM uses APP
sensor information to aid in determining line pressure, shift scheduling and TCC operation. Failure of this
sensor will cause the transmission to operate at higher line pressure to avoid damage to the transmission. This
higher line pressure causes harsh upshifts and harsh engagements.
Throttle Position (TP) Sensor
The Throttle Position (TP) sensor is a potentiometer mounted on the Throttle Body (TB). The TP sensor
detects the position of the throttle plate and sends this information to the processor assembly as varying
voltage signal.
Transaxle Electronic Control System 3575

The PCM uses the monitored voltage level of the TP sensor for control of Line Pressure Control (LPC), TCC
operation and shift scheduling.
If a malfunction occurs in the TP sensor circuit, the processor will recognize that the TP sensor signal is out of
specification. The processor will then operate the transaxle in a high capacity mode to prevent transaxle
damage.
PCM
The PCM controls operation of the transaxle. Many input sensors provide information to the PCM. The PCM
then controls the actuators which affect transaxle operation.
Transmission Range (TR) Sensor Assembly
The Transmission Range (TR) sensor assembly is an internally mounted sensor that includes the detent
bracket and is located above the main control assembly. The components of the TR sensor are factory adjusted
and is installed as a calibrated assembly. The TR sensor contains electronic circuitry that provides the PCM a
fixed frequency duty cycle for each of the various positions of the manual lever (PARK, REVERSE,
NEUTRAL, DRIVE and LOW to the PCM). The PCM uses the TR sensor signal for engine start, reverse
lamps, LPC , shift scheduling and TCC operation.
Brake Pedal Position (BPP) Switch
The Brake Pedal Position (BPP) switch tells the PCM when the brakes are applied. The BPP switch closes
when the brakes are applied and opens when they are released. The BPP signal is used for the brake shift
interlock actuation.
Turbine Shaft Speed (TSS) Sensor
This Turbine Shaft Speed (TSS) sensor is a Hall-effect pickup that sends a signal to the PCM that indicates
transaxle turbine shaft input speed. The TSS sensor provides converter turbine speed information for TCC
strategy. Also used in determining static LPC pressure settings.
Output Shaft Speed (OSS) Sensor
The Output Shaft Speed (OSS) sensor is a Hall-effect pickup, located on the transfer shaft drive gear, that
sends a signal to the PCM to indicate transmission output speed. The OSS is used for TCC control and shift
scheduling.
Solenoid Body
NOTICE: If the solenoid body identification and strategy does not match the solenoid body information
in the Powertrain Control Module (PCM), transaxle damage or driveability concerns can occur.
The solenoid body contains 7 solenoids, 5 shift solenoids (Shift Solenoid A (SSA), Shift Solenoid B (SSB),
Shift Solenoid C (SSC), Shift Solenoid D (SSD) and Shift Solenoid E (SSE)), TCC solenoid and LPC
solenoid. The Transmission Fluid Temperature (TFT) is also located in the solenoid body. The solenoid body
is serviced as an assembly.
Transaxle Electronic Control System 3576

The solenoid body has a unique strategy data file that must be downloaded to the PCM. There is a 7-digit
solenoid body identification and a 13-digit solenoid body strategy for each solenoid body. Any time a new
solenoid body is installed or a new transaxle is installed, the scan tool must be used to get the solenoid body
strategy data file and download it into the PCM.
If the PCM is replaced, the solenoid body identification and solenoid body strategy must be downloaded into
the PCM.
Line Pressure Control (LPC) Solenoid
The LPC solenoid is a Variable Force Solenoid (VFS) that varies hydraulic pressure by actuating a hydraulic
valve.
The PCM applies variable current to the LPC solenoid which varies pressure in the VBS LINE hydraulic
circuit to the main pressure regulator valve. Refer to Hydraulic Circuits for additional information.
The LPC solenoid uses inversely proportional operation. As the current from the PCM decreases, the pressure
from the solenoid increases. As the current from the PCM increases, the pressure from the solenoid decreases.
The LPC solenoid is supplied hydraulic pressure from the SOL FD circuit.
With zero current, the LPC solenoid fully opens the hydraulic valve which applies the maximum amount of
hydraulic pressure to the Main Pressure Regulator Valve through the VBS LINE hydraulic circuit and applies
maximum line pressure in the LINE hydraulic circuit. With maximum current to the solenoid, the hydraulic
valve fully closes the outlet port for minimum pressure to the VBS LINE hydraulic circuit to lower the line
pressure in the LINE hydraulic circuit.
Line Pressure Control (LPC) Inversely Proportional Variable Force Solenoid (VFS)
Torque Converter Clutch (TCC) Solenoid
The TCC solenoid is a VFS that varies hydraulic pressure by actuating a hydraulic valve.
Line Pressure Control (LPC) Inversely Proportional Variable Force Solenoid (VFS) 3577
The PCM applies variable current to the TCC solenoid which varies pressure in the VBS TCC hydraulic
circuit to the TCC regulator valve and the TCC control valve. Refer to Hydraulic Circuits for additional
information.
The TCC solenoid uses proportional operation. As the current from the PCM decreases, the pressure from the
solenoid decreases. As the current from the PCM increases, the pressure from the solenoid increases. The
TCC solenoid is supplied hydraulic pressure from the SOL FD circuit.
With zero current, the TCC solenoid fully closes the hydraulic valve which applies the minimum amount of
hydraulic pressure to the TCC regulator valve through the VBS TCC hydraulic circuit and releases the TCC .
With maximum current to the solenoid, the hydraulic valve fully opens the outlet port for maximum pressure
to the VBS TCC hydraulic circuit to apply the TCC .
Torque Converter Clutch (TCC) Proportional Variable Force Solenoid (VFS)
Shift Solenoid A (SSA), Shift Solenoid B (SSB), Shift Solenoid C (SSC) and Shift Solenoid D (SSD)
Shift solenoids A-D are variable force type solenoids that vary hydraulic pressure by actuating a hydraulic
valve.
The PCM applies variable current to the shift solenoids which varies pressure in the hydraulic circuit to the
regulator and latch valves of the clutch that it controls. Refer to Hydraulic Circuits for additional information.
SSA and SSC use proportional operation. As the current from the PCM decreases, the pressure from the
solenoid decreases. As the current from the PCM increases, the pressure from the solenoid increases. SSA and
SSC are supplied hydraulic pressure from the SOL FD circuit.
With zero current, SSA and SSC fully close the hydraulic valves which applies zero amount of hydraulic
pressure to the clutch regulator and latch valves of the clutch that it controls and releases the clutch. With
maximum current to the solenoids, the hydraulic valves are fully open for maximum pressure to the clutch
regulator and latch valves to apply the clutch.
Torque Converter Clutch (TCC) Proportional Variable Force Solenoid (VFS) 3578
Shift Solenoid A (SSA) and Shift Solenoid C (SSC) Proportional Variable Force Type Solenoids

1 7G136 Shift Solenoid A (SSA) Variable Force Solenoid
(VFS)
2 7G136 Shift Solenoid C (SSC) VFS
SSB and SSD use inversely proportional operation. As the current from the PCM decreases, the pressure from
the solenoid increases. As the current from the PCM increases, the pressure from the solenoid decreases. SSB
and SSD are supplied hydraulic pressure from the SOL FD circuit.
With zero current, SSB and SSD fully open the hydraulic valves which applies maximum hydraulic pressure
to the clutch regulator and latch valves to apply the clutch that it controls. With maximum current to the
solenoids, the hydraulic valve is fully closed to apply zero amount of hydraulic pressure to the clutch regulator
and latch valves of the clutch that it controls and releases the clutch.
Shift Solenoid B (SSB) and Shift Solenoid D (SSD) Inverse Proportional Variable Force Type Solenoids
Shift Solenoid A (SSA) and Shift Solenoid C (SSC) Proportional Variable Force Type Solenoids3579

1 7G383 Shift Solenoid B (SSB) Variable Force Solenoid (VFS)
2 7G383 Shift Solenoid D (SSD) VFS
Shift Solenoid E (SSE)
SSE is an ON/OFF solenoid. When SSE is in the ON position, SSD controls the clutch regulator and latch
valves to apply the low/reverse clutch. When SSE is in the OFF position, SSD controls the clutch regulator
and latch valves to apply the overdrive (4, 5, 6) clutch. Refer to Hydraulic Circuits for additional information.
SSE is supplied hydraulic pressure from the SOL FD circuit. When SSE is OFF, the solenoid supply is
blocked and the outlet port (ON/OFF SIG circuit) is connected to the exhaust port. When SSE is ON, the
exhaust port is blocked and the solenoid supply is connected to the outlet port (ON/OFF SIG circuit),
supplying pressure to the clutch control bypass valve.
Shift Solenoid E (SSE) ON/OFF Solenoid
Shift Solenoid B (SSB) and Shift Solenoid D (SSD) Inverse Proportional Variable Force Type Solenoids
3580
Shift Solenoid E (SSE) ON/OFF Solenoid 3581

Transaxle Operation
Transaxle Operation Overview
Torque Converter
This transaxle uses a torque converter with the following elements:
• Impeller
• Turbine
• Reactor
• Torque Converter Clutch (TCC)
For component information, refer to Torque Converter in this section.
Planetary Gearsets
Operation of this transaxle involves the use of the following planetary gearsets:
• Front
• Center
• Rear
Apply Clutches
This transaxle uses the following clutches to operate the 3 planetary gearsets:
• Forward (1, 2, 3, 4) clutch

• Low/reverse clutch
• Low One-Way ClutOWC)
• Direct (3, 5, R) clutch
• Intermediate (2, 6) clutch
• Overdrive (O/D) (4, 5, 6) clutch
For additional information about planetary gearsets or the apply clutches, refer to Mechanical Components
and Functions in this section.
Hydraulic System
The hydraulic system of this transaxle consists of the following components:
• Transmission fluid pump with filter

• Transmission fluid filler tube with transmission fluid level indicator
• Main control assembly (valve body and solenoid body)
For component information, refer to Hydraulic System in this section.
Electronic Operation
Transaxle Operation 3582

The PCM controls the operation of the transaxle with the following solenoids:
• Line Pressure Control (LPC) solenoid

• Shift Solenoid A (SSA)
• Shift Solenoid B (SSB)
• Shift Solenoid C (SSC)
• Shift Solenoid D (SSD)
• Shift Solenoid E (SSE)
• TCC solenoid
For solenoid information, refer to Transaxle Electronic Control System in this section.
Park Position
Mechanical Operation
Apply components:
• Park pawl engaged, holding the final drive assembly stationary

• Low/reverse clutch applied
Planetary Gearset Operation
Front planetary gearset driven components:
• None
Center planetary gearset driven components:
Mechanical Operation 3583

• Sun gear
Rear planetary gearset driven components:
• None
Front planetary gearset held components:
• Planetary carrier assembly (splined to final drive assembly, held stationary by park pawl)
Center planetary gearset held components:
• Center ring gear (splined to rear planetary carrier)
Rear planetary gearset held components:
• Planetary carrier
• Rear ring gear (splined to front carrier)
Park Position Clutch Application Chart
Gear/Manual Lever Direct (3, Overdrive (4, Forward (1, Low/ Reverse Intermediate
Position 5, R) 5, 6) 2, 3, 4) (L, R) (2, 6) One-Way
PARK X
For component information, refer to Mechanical Components and Functions in this section.
Park Position Power Flow
Planetary Gearset Operation 3584

Hydraulic Operation
Line pressure hydraulic circuits:
• Line pressure from the pump is supplied to the main pressure regulator valve, low reverse/456
regulator valve, manual valve, solenoid regulator valve and control pressure regulator.
• Line pressure is controlled by the position of the main pressure regulator valve.
• The position of the main pressure regulator valve is controlled by varying pressure from the LPC
solenoid through the VBS LINE circuit.
Torque converter circuits:
• Regulated line pressure from the main pressure regulator valve is directed to the TCC control valve
through the CONV FD hydraulic circuit.
• When the TCC is released, CONV FD pressure is directed to the TCC RELEASE circuit by the TCC
control valve. Pressure from the TCC RELEASE circuit releases the TCC .
• Fluid from the TCC RELEASE returns to the TCC control valve through the TCC APPLY circuit.
Cooler and lubrication hydraulic circuits:
• The TCC control valve directs fluid from the TCC APPLY circuit (return circuit from the torque
converter when the TCC is released) to the COOLER FD circuit.
• In the COOLER FD circuit, transmission fluid flows through the transmission fluid cooler or the
thermal bypass valve to the LUBE circuit in the input shaft to supply lubrication to the transaxle.
Solenoid hydraulic circuits:
• The LPC solenoid applies varying pressure to the main pressure regulator valve through the VBS
LINE hydraulic circuit. The LPC solenoid regulates line pressure by controlling the position of the
main pressure regulator valve.
• SSD applies pressure to the low reverse/456 regulator and latch valves to apply the low/reverse
clutch.
• SSE applies pressure to the clutch control bypass valve to position the valve to direct regulated line
pressure in the CBR1/C456 circuit to the low/reverse clutch.
Clutch hydraulic circuits:
• Line pressure from the pump is supplied to the low reverse/456 regulator valve. To apply the
low/reverse clutch, SSD supplies varying solenoid pressure to the low reverse/456 regulator and latch
valves. As the low reverse/456 regulator valve moves, it supplies the clutch control bypass valve and
low reverse/456 latch valve with regulated line pressure through the CBR1/C456 circuit. The latch
valve directs the regulated line pressure to the opposite side of the regulator valve through the
CBR1/C456 FDBK circuit for gradual low/reverse clutch engagement.
• Regulated line pressure at the clutch control bypass valve in the CBR1/C456 circuit is directed to the
low/reverse clutch through the CBR1 circuit to apply the clutch.
For additional hydraulic circuit information, refer to Hydraulic Circuits in this section.
Electrical Operation
Solenoid operation:
Hydraulic Operation 3585

Park Position Solenoid Operation Chart
Shift Solenoid
Base Selector PCM SSA (VFS) SSB (VFS) SSC SSD (VFS) SSE TCC
Lever Commanded NL (1, 2, 3, NH (3, 5, (VFS) NL NH (L, R/4, (On/Off) (VFS)
Position Gear 4) R) (2, 6) 5, 6) NC NL
NH = Normally high
NL = Normally low
Printable / zoomable view of this graphic
Reverse Position
Electrical Operation 3586

Apply components:

• Direct (3, 5, R) clutch applied
• Sun gear (does not contribute to power flow)
• Sun gear
• None
• Center ring (does not contribute to power flow)

Reverse Position Clutch Application Chart
REVERSE X X
Reverse Position Power Flow
Hydraulic Operation

• SSB applies pressure to the 35R regulator and latch valves to apply the direct (3, 5, R) clutch.
• SSD applies pressure to the low reverse/456 regulator valve to apply the low/reverse clutch.
pressure in the CBR1/C456 circuit to the CBR1 circuit to apply the low/reverse clutch.
• Line pressure supplied to the manual valve is directed to the clutch control bypass valve through the
REVERSE circuit.
• The clutch control bypass valve directs the REVERSE circuit to the 35R regulator valve through the
C35R FD circuit, DRIVE 2/C35R FD shuttle ball and DRIVE 2/C35R FD circuit. To apply the direct
(3, 5, R) clutch, SSB applies varying solenoid pressure to the 35R regulator and latch valves. As the
35R regulator valve moves, it supplies the direct (3, 5, R) clutch and 35R latch valve with regulated
line pressure through the C35R circuit. The 35R latch valve directs the regulated line pressure to the
opposite side of the 35R regulator valve through the C35R FDBK circuit for gradual direct (3, 5, R)
clutch engagement.
valves. As the regulator valve moves, it supplies the clutch control bypass valve and low reverse/456
latch valve with regulated line pressure through the CBR1/C456 circuit. The low reverse/456 latch
Solenoid operation:
Reverse Position Solenoid Operation Chart
Shift Solenoid
NH = Normally high
NL = Normally low

Neutral Position
Apply components:
• None
• Sun gear

• None
• None
• Ring gear
Neutral Position Clutch Application Chart
NEUTRAL X
Power Flow
Hydraulic Operation

clutch.
Solenoid operation:
Neutral Position Solenoid Operation Chart
Shift Solenoid

NH = Normally high
NL = Normally low
1st Gear Above 8 km/h (5 mph)

NOTE: The transaxle operates differently in 1st gear above and below 8 km/h (5 mph). For transaxle
operation below 8 km/h (5 mph), refer to Manual LOW Position and 1st Gear Below 8 km/h (5 mph) in this
section.
Apply components:

• OWC
• Ring gear
• Sun gear
• Ring gear
• Sun gear
• Ring gear
• Rear planetary carrier (does not contribute to power flow)
1st Gear Above 8 km/h (5 mph) Clutch Application Chart
Direct (3, 5, Overdrive (4, 5, Forward (1, 2, 3, Low/ Reverse (L, Intermediate (2,
Gear R) 6) 4) R) 6) One-Way
1st X X
gear

Power Flow
Hydraulic Operation
• SSA applies pressure to the 1234 regulator and latch valves to apply the forward (1, 2, 3, 4) clutch.
• SSD releases pressure to the low reverse/456 regulator and latch valves to release the low/reverse
clutch.
• SSE releases pressure to the clutch control bypass valve to position it so that regulated line pressure
supplied in the CBR1/C456 circuit for 4th, 5th and 6th gear will apply the O/D (4, 5, 6) clutch.
Power Flow 3595

• SSD removes pressure from the low reverse/456 regulator and latch valves which positions the valves
to block line pressure and release the low/reverse clutch. Solenoid pressure from SSE is removed
from the clutch control bypass valve to position it to apply the O/D (4, 5, 6) clutch.
• Line pressure is supplied to the 1234 regulator valve by the manual valve in the DRIVE and LOW
position. To apply the forward (1, 2, 3, 4) clutch, SSA supplies varying solenoid pressure to the 1234
regulator and latch valves. As the 1234 regulator valve moves, it supplies the forward (1, 2, 3, 4)
clutch and 1234 latch valve with regulated line pressure through the C1234 circuit. The 1234 latch
valve directs the regulated line pressure to the opposite side of the regulator valve through the C1234
FDBK circuit for gradual forward (1, 2, 3, 4) clutch engagement.
Solenoid operation:
1st Gear Above 8 km/h (5 mph) Solenoid Operation Chart
Shift Solenoid
D 1 On On Off On Off Off
NH = Normally high
NL = Normally low

2nd Gear
Apply components:

• Ring gear
• Sun gear
• Ring gear
• Ring gear
• Sun gear

• None
• Sun gear
2nd Gear Clutch Application Chart
2nd X X
gear
Power Flow
Hydraulic Operation

• SSC applies pressure to the 26 regulator and latch valves to apply the intermediate (2, 6) clutch.
regulator and latch valves. As the regulator valve moves, it supplies the forward (1, 2, 3, 4) clutch and
1234 latch valve with regulated line pressure through the C1234 circuit. The 1234 latch valve directs
the regulated line pressure to the opposite side of the regulator valve through the C1234 FDBK circuit
for gradual forward (1, 2, 3, 4) clutch engagement.
positions. To apply the intermediate (2, 6) clutch, SSC supplies varying solenoid pressure to the 26
regulator and latch valves. As the 26 regulator valve moves, it supplies the intermediate (2, 6) clutch
and 26 latch valve with regulated line pressure through the CB26 circuit. The 26 latch valve directs
the regulated line pressure to the opposite side of the 26 regulator valve through the CB26 FDBK
circuit for gradual intermediate (2, 6) clutch engagement.
For additional hydraulic circuit and information, refer to Hydraulic Circuits in this section.
Solenoid operation:
2nd Gear Solenoid Operation Chart
Shift Solenoid
D 2 On On On On Off Off
NH = Normally high
NL = Normally low

3rd Gear
Apply components:


• Ring gear
• Sun gear
• Ring gear
• Sun gear
• Ring gear
• Sun gear
• None
• None
3rd Gear Clutch Application Chart
3rd X X
gear
Power Flow

Hydraulic Operation
• SSC releases pressure to the 26 regulator and latch valves to release the intermediate (2, 6) clutch.
latch valve with regulated line pressure through the C1234 circuit. The 1234 latch valve directs the
regulated line pressure to the opposite side of the 1234 regulator valve through the C1234 FDBK
Power Flow 3602

circuit for gradual forward (1, 2, 3, 4) clutch engagement.
• Solenoid pressure from SSC is removed from the 26 regulator and latch valves which positions the
valves to block line pressure and release the intermediate (2, 6) clutch.
• Line pressure from the pump is directed to the clutch control bypass valve by the manual valve
through the DRIVE hydraulic circuit. The clutch control bypass valve directs the pressure to the 35R
regulator valve through the TCC regulator valve, DRIVE 2 circuit, DRIVE 2/C35R FD shuttle ball
and DRIVE 2/C35R FD circuit. SSB applies varying solenoid pressure to the 35R regulator and latch
valves. As the regulator valve moves, it supplies the direct (3, 5, R) clutch and 35R latch valve with
regulated line pressure through the C35R circuit. The 35R latch valve directs the regulated line
pressure to the opposite side of the 35R regulator valve through the C35R FDBK circuit for gradual
direct (3, 5, R) clutch engagement.
Solenoid operation:
3rd Gear Solenoid Operation Chart
Shift Solenoid
D 3 On Off Off On Off Off
NH = Normally high
NL = Normally low

4th Gear
Apply components:

• O/D (4, 5, 6) clutch

• Ring gear
• Sun gear
• Ring gear
• Sun gear
• None
• None
4th Gear Clutch Application Chart
4th X X
gear
Power Flow

Hydraulic Operation
• Fluid from the TCC RELEASE circuit returns to the TCC control valve through the TCC APPLY
circuit.
• SSB releases pressure to the 35R clutch regulator and latch valves to release the direct (3, 5, R)
clutch.
• SSD applies pressure to the low reverse/456 regulator and latch valves to apply the O/D (4, 5, 6)
clutch.
Power Flow 3606

1234 latch valve with regulated line pressure through the C1234 circuit. The 1234 latch valve directs
the regulated line pressure to the opposite side of the 1234 regulator valve through the C1234 FDBK
• Solenoid pressure from SSB is removed from the 35R regulator and latch valves which positions the
valves to block line pressure and release the direct (3, 5, R) clutch.
• Line pressure from the pump is supplied to the low reverse/456 regulator valve. SSD supplies varying
solenoid pressure to the low reverse/456 regulator and latch valves. As the regulator valve moves, it
supplies the clutch control bypass valve and low reverse/456 latch valve with regulated line pressure
through the CBR1/C456 circuit. The low reverse/456 latch valve directs the regulated line pressure to
the opposite side of the low reverse/456 regulator valve through the CBR1/C456 FDBK circuit for
gradual clutch engagement.
O/D (4, 5, 6) clutch through the C456 circuit to apply the clutch.
• Regulated line pressure in the C456 also supplies the latch pressure for the clutch control bypass
valve.
Solenoid operation:
4th Gear Solenoid Operation Chart
Shift Solenoid
D 4 On On Off Off Off Off
NH = Normally high
NL = Normally low

5th Gear
Apply components:
• O/D (4, 5, 6) clutch


• Sun gear
• None
• None
• None
5th Gear Clutch Application Chart
5th X X
gear
Power Flow

Hydraulic Operation
clutch.
• SSA releases pressure to the 1234 regulator and latch valves to release the forward (1, 2, 3, 4) clutch.
Power Flow 3610

the opposite side of the regulator valve through the CBR1/C456 FDBK circuit for gradual clutch
engagement.
• Regulated line pressure in the C456 also supplies the latch pressure for the clutch control bypass
valve.
• Solenoid pressure from SSA is removed from the 1234 regulator and latch valves which positions the
valves to block line pressure and release the forward (1, 2, 3, 4) clutch.
and DRIVE 2/C35R FD circuit. SSB applies varying solenoid pressure to the 35R regulator and latch
valves. As the regulator valve moves, it supplies the direct (3, 5, R) clutch and 35R latch valve with
regulated line pressure through the C35R circuit. The 35R latch valve directs the regulated line
pressure to the opposite side of the 35R regulator valve through the C35R FDBK circuit for gradual
direct (3, 5, R) clutch engagement.
Solenoid operation:
5th Gear Solenoid Operation Chart
Shift Solenoid
PCM SSA (VFS) SSD (VFS) SSE
Base Selector Commanded NL (1, 2, 3, SSB (VFS) SSC (VFS) NH (L, R/4, 5, (On/Off)
Lever Position Gear 4) NH (3, 5, R) NL (2, 6) 6) NC
D 5 Off Off Off Off Off
NH = Normally high
NL = Normally low

6th Gear Torque Converter Clutch (TCC) Applied
Apply components:
• O/D (4, 5, 6) clutch

• TCC

• Ring gear
• None
• None
• Sun gear
6th Gear TCC Applied Clutch Application Chart
Gear R) 6) 4) R) 6) TCC
6th X X X
gear
Power Flow

Hydraulic Operation
• When the torque converter is applied, line pressure from the manual valve is directed to the TCC
regulator valve by the clutch control bypass valve through the DRIVE 2 circuit. The TCC solenoid
supplies varying solenoid pressure to the TCC regulator valve and the TCC control valve to position
the valves to apply the TCC .
• As the TCC regulator valve moves, it supplies the TCC control valve with regulated line pressure
through the REG APPLY circuit. The TCC control valve directs the REG APPLY circuit to the TCC
APPLY circuit to apply the TCC .
• Pressure from the torque converter returns to the TCC control valve through the TCC RELEASE
circuit.
through the CONV FD hydraulic circuit. When the TCC is applied, CONV FD pressure supplies the
COOLER FD circuit which circulates through the transmission fluid cooler or the thermal bypass
valve.
clutch.
• SSB releases pressure to the 35R regulator and latch valves to release the direct (3, 5, R) clutch.
• SSC applies pressure to the 26 regulator and latch valves to apply the direct (2, 6) clutch.
Power Flow 3614

• The TCC solenoid applies pressure to the TCC control valve and the TCC regulator valve to apply the
TCC .
the opposite side of the low reverse/456 regulator valve through the CBR1/C456 FDBK circuit for
gradual clutch engagement.
• Regulated line pressure in the C456 circuit also supplies the latch pressure for the clutch control
bypass valve.
• Solenoid pressure from SSB is removed from the 35R regulator and latch valves which positions the
valves to block line pressure and release the direct (3, 5, R) clutch.
positions. To apply the intermediate (2, 6) clutch, SSC supplies varying solenoid pressure to the 26
regulator and latch valves. As the regulator valve moves, it supplies the intermediate (2, 6) clutch and
26 latch valve with regulated line pressure through the CB26 circuit. The 26 latch valve directs the
regulated line pressure to the opposite side of the regulator valve through the CB26 FDBK circuit for
gradual intermediate (2, 6) clutch engagement.
Solenoid operation:
6th Gear TCC Applied Solenoid Operation Chart
Shift Solenoid
D 6 Off On On Off Off On
NH = Normally high
NL = Normally low

Manual LOW Position and 1st Gear Below 8 km/h (5 mph) Solenoid Operation Chart
NOTE: The transaxle operates differently in first gear above and below 8 km/h (5 mph). For transaxle
operation above 8 km/h (5 mph), refer to 1st Gear Above 8 km/h (5 mph) in this section.
Apply components:

• Low/reverse clutch

• Low OWC
• Ring gear
• Sun gear
• None
• Sun gear
• Ring gear
• Rear planetary carrier (does not contribute to power flow)
Manual LOW Position and 1st Gear Below 8 km/h (5 mph) Clutch Application Chart
1st X X X
gear
Power Flow

Hydraulic Operation
clutch.
regulator and latch valves. As the 1234 regulator valve moves, it supplies the forward (1, 2, 3, 4)
Power Flow 3618

clutch and 1234 latch valve with regulated line pressure through the C1234 circuit. The latch valve
directs the regulated line pressure to the opposite side of the regulator valve through the C1234 FDBK
valve directs the regulated line pressure to the opposite side of the low reverse/456 regulator valve
through the CBR1/C456 FDBK circuit for gradual low/reverse clutch engagement.
Solenoid operation:
Manual LOW Position and 1st Gear Below 8 km/h (5 mph) Solenoid Operation Chart
Shift Solenoid
NH = Normally high
NL = Normally low

5th Gear Failsafe
5th Gear Failsafe Description
When the transaxle has an electrical, hydraulic or mechanical failure, the PCM removes ground (control) from
the shift, TCC and LPC solenoids. The uncontrolled solenoids default to their normal states. SSB , SSD and
the LPC solenoid are normally high solenoids which means in their normal state, they provide high pressure
to the valves they control. This provides only 5th gear with maximum line pressure.

Apply components:
• O/D (4, 5, 6) clutch

• Sun gear
• None
• None
• None
5th Gear Failsafe Clutch Application Chart
5th X X
gear
Power Flow

Hydraulic Operation
solenoid through the VBS LINE circuit. In 5th gear failsafe, full solenoid pressure is supplied by the
LPC solenoid to the main pressure regulator valve for maximum line pressure.
• Pressure from the main pressure regulator valve is directed to the TCC control valve through the
CONV FD hydraulic circuit.
• Fluid from the TCC RELEASE circuit returns to the TCC control valve through the TCC APPLY
circuit.
• The LPC solenoid applies maximum solenoid output pressure to the main pressure regulator valve
through the VBS LINE hydraulic circuit. The LPC solenoid defaults to maximum output to provide
maximum line pressure.
• SSD applies maximum solenoid pressure to the low reverse/456 clutch regulator and latch valves to
apply the O/D (4, 5, 6) clutch.
• SSB applies maximum solenoid pressure to the 35R clutch regulator and latch valves to apply the
direct (3, 5, R) clutch.
• Line pressure from the pump is supplied to the low reverse/456 regulator valve. SSD supplies
maximum solenoid pressure to the low reverse/456 regulator and latch valves to provide full line
Power Flow 3622

pressure in the CBR1/C456 circuit.
• Maximum line pressure at the clutch control bypass valve in the CBR1/C456 circuit is directed to the
• Pressure in the C456 also supplies the latch pressure for the clutch control bypass valve.
and DRIVE 2/C35R FD circuit. SSB applies maximum solenoid pressure to the 35R regulator and
latch valves to provide full line pressure to the direct (3, 5, R) clutch.
Solenoid operation:
5th Gear Failsafe Solenoid Operation Chart
Shift Solenoid
PCM SSA (VFS) SSD (VFS) SSE
Base Selector Commanded NL (1, 2, 3, SSB (VFS) SSC (VFS) NH (L, R/4, 5, (On/Off)
Lever Position Gear 4) NH (3, 5, R) NL (2, 6) 6) NC
D 5 Off Off Off Off Off
NH = Normally high
NL = Normally low


DIAGNOSIS AND TESTING Procedure revision date: 06/03/2011
Diagnostic Strategy
Troubleshooting an electronically controlled automatic transmission is simplified by using the proven method
of diagnosis. One of the most important things to remember is that there is a definite procedure to follow.
NOTE: Do not take shortcuts or assume that critical checks or adjustments have already been made.
Follow the procedures as written to avoid missing critical components or steps.
To correctly diagnose a concern, have the following publications available:
• Transmission reference manual

• Powertrain Control/Emissions Diagnosis (PC/ED) manual
• TSBs
• Wiring diagrams manual
These publications provide the information required when diagnosing transmission concerns.
Use the Diagnostic Flow C as a guide and follow the steps as indicated.
Preliminary Inspection
• Know and understand the customer concern.

• Verify the concern by operating the vehicle.
• Check the fluid levels and condition.
• Check for non-factory add-on items.
• Check selector lever linkage for correct adjustment.
• Check TSB messages regarding the concern.
Diagnostics
• Carry out OBD test procedures, KOEO and KOER self-tests.

• Record all DTCs.
• Repair all non-transmission codes first.
• Repair all transmission codes second.
• Clear all continuous codes and attempt to repeat them.
• Repair all continuous codes.
• If only pass codes are obtained, refer to Diagnosis By Symptom for further information and diagnosis.
Follow the diagnostic sequence to diagnose and repair the concern the first time.
Diagnostic Strategy 3625

Diagnostic Strategy 3626

Transaxle/Transmission â 6F35 Workshop Manual
Diagnostic Flow Chart
Special Tool(s)

Prior to carrying out the flow test, the following items should be checked:
• Know and understand the customer concern.

• Verify the concern by operating the vehicle.
• Check the transmission fluid level and condition.
• Check for non-factory installed items and verify correct installation.
• Check the selector lever linkage adjustments.
• Check TSB messages for vehicle concerns.
• Carry out both KOEO and KOER self-test.
• Record all DTCs.
Diagnostic Flow Chart
Test Result Action

1)â Were any DTCs Yes
recorded? • REPAIR all hard DTCs. FOLLOW the pinpoint tests. REFER
to the Powertrain Control/Emissions Diagnosis (PC/ED)
manual first, then this workshop manual, GO to Step 2.
No
• REFER to Diagnosis By Symptom , GO to Step 5.
2)â Are any continuous Yes
test memory codes present? • CLEAR codes and CARRY OUT drive cycle test, GO to Step
3.
No
• GO to Step 4.
3)â Did the continuous test Yes
memory codes reappear? • REPAIR all continuous test memory codes. FOLLOW the
pinpoint tests. REFER to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual, then the transmission reference
manual, then this workshop manual, GO to Step 4.
No
• GO to Step 4.
4)â Is the concern Yes
repaired? • CARRY OUT the final self-test and verify no DTCs are
present. CLEAR memory codes.
Diagnostic Flow Chart 3627

No • REFER to Diagnosis By Symptom , GO to Step 5.

5)â Are there any electrical Yes
concerns? • INSTALL the scan tool. CARRY OUT static and drive test
with the scan tool, GO to Step 6.
No
• REFER to the hydraulic and mechanical routine to diagnose
and repair the concern, GO to Step 7.
6)â Was the transmission Yes
concern corrected when the • REFER to the Powertrain Control/Emissions Diagnosis
scan tool was installed? (PC/ED) manual, intermittent fault diagnosis section and use
the scan tool to diagnose cause of concern in the processor,
vehicle harness or external inputs (sensors or switches).
No
• REFER to the hydraulic and mechanical routine to diagnose
the concern, GO to Step 7.
7)â Is the concern Yes
repaired? • CARRY OUT the final self-test and verify no DTCs are
present. CLEAR memory codes.
No
• Concern should have been repaired. GO back through the
Diagnostic Flow Chart and review other components that may
have contributed to the concern. CHECK and DIAGNOSE
those components. Get assistance from other sources.
Diagnostic Flow Chart 3628

Preliminary Inspection
Material
Item Specification
Motorcraft® MERCON® LV MERCON®
Automatic Transmission Fluid LV
XT-10-QLVC
The following items must be checked prior to beginning the diagnostic procedures.
Know and Understand the Concern
In order to correctly diagnose a concern, first understand the customer complaint or condition. Customer
contact may be required in order to begin to verify the concern. Understand the conditions as to when the
concern occurs. For example:
• Hot or cold vehicle temperature

• Hot or cold ambient temperature
• Vehicle driving conditili>
• Vehicle loaded/unloaded
After understanding when and how the concern occurs, proceed to verifying the concern.
Verification of Condition
This section provides information which is used in determining the actual cause of customer concern and
carrying out the appropriate procedures.
The following procedures must be used when verifying customer concerns for the transmission.
Determine Customer Concern
NOTE: Some transaxle conditions may cause engine concerns. The torque converter not disengaging may
stall the engine.
Determine customer concerns relative to vehicle use and dependent driving conditions, paying attention to the
following items:
• Hot or cold vehicle operating temperature

• Hot or cold ambient temperatures
• Type of terrain
• Vehicle loaded/unloaded
• City/highway driving
• Upshift
• Downshift
• Coasting
Preliminary Inspection 3629

• Engagement
• Noise/vibration - check for engine rpm , vehicle speed, shift, gear, range or temperature dependencies.
Check Transmission Fluid Level and Condition
NOTICE: Do not drive the vehicle if the transmission fluid level indicator shows the transmission fluid
is below the minimum transmission fluid level mark or internal failure could result.
If the vehicle has been operated for an extended period of time at highway speeds, in city traffic, in hot
weather or while pulling a trailer, the transmission fluid may need to cool down to obtain an accurate reading.
The transmission fluid level reading on the transmission fluid level indicator will differ depending on
operating and ambient temperatures. The correct reading should be within the crosshatch area.
Transmission Fluid Level Check NOTE: Transmission fluid should be checked at normal operating
temperature 85°C-93°C (185°F-200°F) on a level surface. Normal operating temperature can be reached after
approximately 32 km (20 mi) of driving and can be checked using the scan tool.
Check the transmission fluid level during normal maintenance. If the transaxle starts to slip, shifts slowly or
shows signs of leaking, the transmission fluid level should be checked.
1. With the selector lever in PARK, engine at idle, brake pedal applied, move the selector lever through
each gear range and allow engagement of each gear. Place the selector lever in the PARK position.
4. Install the transmission fluid level indicator back in the transmission fluid filler tube until it is fully
seated.
5. Remove the transmission fluid level indicator. The transmission fluid level should be within the
crosshatch area.
Item Description
1 Correct transmission fluid level at operating temperature 85°C-93°C (185°F-200°F)
2 Minimum transmission fluid level mark
3 Maximum transmission fluid level mark
4 Flat tow transmission fluid level
High Transmission Fluid Level

High transmission fluid level may cause the transmission fluid to become aerated due to the churning action
of the rotating internal parts. This will cause erratic control pressure, foaming, loss of transmission fluid from
the vent tube and possible transaxle malfunction and/or damage. If an overfill reading is indicated, refer to
Transmission Fluid Drain and Refill in this section.
Low Transmission Fluid Level
Low transmission fluid level could result in poor transaxle engagement, slipping, malfunction and/or damage.
This could also indicate a leak in one of the transaxle seals or gaskets.
Adding Transmission Fluid
NOTICE: The use of any type of transmission fluid other than specified could result in transaxle
malfunction and/or damage.
If transmission fluid needs to be added, add transmission fluid in 0.25L (1/2 pt) increments through the
transmission fluid filler tube with the selector lever in PARK and the engine idling. Do not overfill the
transmission. For transmission fluid type, refer to Material chart in this section.
Flat Tow Fluid Level
Recreati flat towing of the vehicle may require the transmission fluid to be set to a lower fluid level. This will
prevent damage to the transmission. The transmission fluid level is within the normal operating range and will
not require the transmission fluid level to be readjusted after recreational towing.
Transmission Fluid Condition Check
1. Check the transmission fluid level.
2. Hold the transmission fluid level indicator over a white facial tissue and allow the transmission fluid
to drip onto the facial tissue and examine the stain.
3. Observe the color and the odor. Under normal circumstances, the color should be dark red, not brown
or black or have a burnt odor.
4. If evidence of solid material is found, remove the transmission fluid pan for further inspection.
5. If the stain is a foamy pink color, this may indicate coolant or water in the transaxle. Inspect the
engine cooling system at this time.
6. If transmission fluid contamination or transaxle failure is confirmed by the sediment in the

transmission fluid, disassemble and thoroughly clean the transaxle, including the torque converter,
cooler bypass valve, coolers and cooler tubes.
7. Carry out diagnostic checks and adjustments, refer to Diagnosis By Symptom in this section.
Water in Transmission Fluid
To correctly repair a transaxle that had water or coolant introduced into the system, completely disassemble,
clean and replace the following parts:
• All internal and external seals

• All friction material; clutches

• Torque converter
• All parts with bonded seals
• All solenoids
• All transmission fluid filters
Prior to installing the transaxle, flush and clean the transmission fluid cooler(s), transmission fluid cooler
tubes and transmission fluid cooler hoses.

Solenoid Body Strategy
Special Tool(s)

Solenoid Body Identification Procedure
1. Using the scan tool, select Powertrain, Transmission and Transion Solenoid Body Identification from
the toolbox icon and follow the instructions displayed on the scan tool.
The solenoid body identification screen displays solenoid body identification information:
• Solenoid body identification 7-digits
• Solenoid body strategy 13-digits
The next screen displays the current solenoid body identification and strategy data file stored
in the TCM . If the solenoid body strategy field is blank, the module contains a partial
transmission solenoid body strategy. This is due to a corrupt or missing file at the time the
programmable parameters were completed.
2. NOTE: The 13-digit solenoid body strategy number consists of only numbers. Letters are not used.
Compare the solenoid body identification and strategy (if available) to the solenoid body service tag
or the replacement solenoid body tag located on top of the transmission case.
Original Solenoid Body Service Tag
Item Description
1 13-digit solenoid body strategy
2 7-digit solenoid body identification
Replacement Solenoid Body Service Tag
Solenoid Body Strategy 3633

Item Description
3. If the solenoid body identification and strategy on the scan tool match the solenoid body service tag or
replacement tag, then the solenoid body identification and strategy are correct for this transmission
and a solenoid body strategy download is not required. If the solenoid body service tag or replacement
tag is missing or damaged so that it is not readable or does not match the identification or strategy on
the scan tool, remove the solenoid body connector and view the solenoid body identification and
strategy printed on the solenoid body connector. If it is not readable, remove the main control cover,
refer to Main Control Cover .
The 7-digit identification number and the 13-digit strategy number are stamped on the solenoid body.
4. NOTICE: If the solenoid body information does not match the module information,
transmission damage or driveability concerns can occur.
Inspect the solenoid body identification and strategy printed on the solenoid body connector and
compare this to the solenoid body service tag on the transmission case. If the solenoid body
identification and strategy printed on the solenoid body connector does not match the solenoid body
service tag or if the solenoid body identification and strategy printed on the solenoid body connector
match the solenoid body service tag on the transmission case but do not match the solenoid body
identification and strategy numbers displayed on the scan tool, a solenoid body strategy data
download is required.
Solenoid Body Identification Tag
Item Description
Replacement Solenoid Body Service Tag 3634

Solenoid Body Strategy Data Download
1. Using the scan tool, select Module Programming and Programmable Parameters under the toolbox
icon and select transmission. Follow the instructions displayed on the scan tool.
There are fields to enter the solenoid body 7-digit identification and 13-digit strategy recorded from
the solenoid body.
2. NOTICE: If the solenoid body information is not correct, transmission damage or driveability
concerns can occur.
Enter the solenoid body identification and strategy.

The scan tool will verify the numbers entered are valid and display a message if the information is not
valid.
The scan tool checks to see if the file is present on the scan tool. If the file is present, the technician
may proceed with downloading the file to the TCM . If the file is not present, the scan tool will need
to be connected to the PTS server to download the file onto the scan tool.
3. Verify the file is present on the scan tool. If the file is present, go to Step 8. If the file is not present,
continue with this procedure.
4. Connect the scan tool to the PTS server.

The screen will display a progress bar when connecting to the network.
5. Follow the instructions on the network to download the strategy file to the scan tool.
The screen will display a progress bar when downloading the strategy file to the scan tool and display
a message if it is downloaded successfully.
6. If the scan tool cannot connect to the PTS server, download the file from www.motorcraft.com.
If the scan tool cannot download a strategy from the web site, a partial strategy will automatically be
downloaded.
7. Reconnect the scan tool to the vehicle.
8. Follow the instructions displayed on the scan tool.
9. If a new solenoid body was installed, compare the 7-digit identification and the 13-digit strategy fields
from the solenoid body to the replacement solenoid body tag provided with the solenoid body service
kit and place it over the existing identification tag.
The scan tool will automatically download the strategy file or partial strategy file to the TCM and will
display a progress bar while downloading. The scan tool will display a message when it is finished
downloading the data that states that the file was downloaded successfully.
Item Description
Solenoid Body Identification Tag 3635


10. NOTICE: If a drive cycle is not completed, the customer may feel erratic shifts and driveability
concerns.
Test drive the vehicle. Refer to Solenoid Body Strategy Drive Cycle in this procedure.
Solenoid Body Strategy Drive Cycle
Carry out the drive cycle after downloading the solenoid body strategy data file to the TCM .
NOTE: Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.
1. NOTE: The engine and transmission must be at normal operating temperature.
Bring the transmission to normal operating temperature.
2. With the engine running and the brake applied, move the selector lever through the gears in the
following order, pausing in each gear for 4 seconds: N, R, N, D, R, D, N. Repeat this pattern 2 times.
If any engagements feel soft or harsh, repeat this procedure.
3. Drive the vehicle and accelerate at a moderate throttle so the upshifts occur at 2,000 rpm up to 80
km/h (50 mph) and brake lightly to a stop. Repeat this pattern 2 times.
4. Drive the vehicle and accelerate at a moderate throttle so the upshifts occur at 3,000 rpm up to 80
km/h (50 mph) and brake lightly to a stop. Repeat this pattern 2 times.
5. With the engine running and the brake applied, move the selector lever through the gears in the
following order, pausing in each gear for 4 seconds: N, R, N, D, R, D, N. Repeat this pattern 2 times.
6. From a stop, accelerate to 25 mph, then release the throttle. Keeping the throttle closed, pull the
selector lever into the "L" position and coast down to 10 mph. Repeat this pattern 2 times.


Road Testing Vehicle
NOTE: If a new or remanufactured transmission assembly is being installed or a new solenoid body is
installed, the TCM will have to be re-programed with a new solenoid body strategy and identification data
file. The solenoid body strategy drive cycle should also be carried out. Refer to Solenoid Body Strategy .
The Shift Point Road Test and Torque Converter Operation Test provide diagnostic information on shift
controls and torque converter operation.
Road Testing Vehicle 3638

Shift Point Road Test
This test verifies the shift control system is operating correctly.
1. Bring engine and transaxle up to normal operating temperature.
2. Operate vehicle with the selector lever in D range.
3. NOTE: Shift speed ranges are approximate for all applications.
Apply minimum throttle and observe the vehicle speed when an upshift occurs and the torque
converter engages using the Shift Speeds chart.
Shift Speeds 2.5L

Light D 1-2 11-16 7-10
Throttle a D 2-3 21-27 13-17
D 3-4 29-37 18-23
D 4-5 45-56 28-35
D 5-6 72-90 45-56
Medium D 1-2 27-43 17-23
Throttle a D 2-3 42-55 26-34
D 3-4 58-77 36-48
D 4-5 77-106 48-66
D 5-6 135-177 84-110
Heavy D 1-2 51-66 32-41
Throttle a D 2-3 79-100 49-62
D 3-4 113-143 70-89
D 4-5 150-190 93-118
D 5-6 201-245 125-152
Shift Speeds 3.0L

Light D 1-2 13-18 8-11
Throttle a D 2-3 19-26 12-16
D 3-4 29-37 18-23
D 4-5 45-56 28-35
D 5-6 72-90 45-56
Shift Point Road Test 3639

Medium D 1-2 32-42 20-26

Throttle a D 2-3 48-61 30-38
D 3-4 63-82 39-51
D 4-5 80-108 50-67
D 5-6 117-159 73-99
Heavy D 1-2 58-72 36-45
Throttle a D 2-3 85-106 53-66
D 3-4 126-156 78-97
D 4-5 151-192 94-119
D 5-6 217-261 135-162
4. With vehicle speed above 43 km/h (27 mph), press the accelerator pedal to Wide Open Throttle
(WOT). The transaxle should shift from 4th to 3rd, or 4th to 2nd, depending on vehicle speed. The
torque converter should disengage.
5. With vehicle speed above 56 km/h (35 mph), move the selector lever from the D range to the L range
and remove foot from accelerator pedal. The transaxle should immediately downshift to 2nd gear.
When vehicle speed drops below 32 km/h (20 mph), the transaxle should downshift into 1st gear.
6. If the transaxle fails to upshift/downshift or the torque converter does not apply and release, refer to
Diagnosis By Symptom in this section for possible causes.
Shift Point Road Test 3640

Torque Converter Diagnosis
Special Tool(s)

Prior to torque converter installation, all diagnostic procedures must be followed. This is to prevent the
unnecessary installation of new or remanufactured torque convertAfter a complete diagnostic evaluation can a
decision be made to install a new or remanufactured torque converter.
Begin with the normal diagnostic procedures as follows:
1. Preliminary inspection
2. Know and understand the customer concern
3. Verify the concern - carry out the Torque Converter Operation Test
4. Carry out diagnostic procedures:

• Run OBD . Refer to Diagnostics .
♦ Repair all non-transmission related DTCs first.
♦ Repair all transmission DTCs.
♦ Rerun OBD test to verify repair.
♦ Carry out Line Pressure Test. Refer to Special Testing Procedures .
♦ Carry out Stall Speed Test. Refer to Special Testing Procedures .
♦ Carry out diagnostic routines. Refer to Diagnosis By Symptom .
♦ Use the index to locate the appropriate routine that best describes the symptom(s).
The routine will list possible components that may cause or contribute to the
symptom. Check each component listed, diagnose and repair as required before
installing a new torque converter.
Torque Converter Operation Test
This test verifies the TCC control system and the torque converter are operating correctly.
1. Carry out self-test and check for DTCs.
2. Connect the scan tool and monitor engine rpm.
3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds with the
selector lever in the (D) position.
4. If the vehicle stalls in (D) at idle with the vehicle at a stop, move the selector lever to manual L
position. If the vehicle stalls, see Torque Converter Operation Concerns, refer to Diagnosis By
Symptom . Repair as required. If the vehicle does not stall in (D), refer to Diagnosis By Symptom .
Torque Converter Diagnosis 3641

Torque Converter Diagnosis 3642

Visual Inspection
This inspection will identify modifications or additions to the vehicle operating system that may affect
diagnosis. Inspect the vehicle for non-Ford factory add-on devices such as:
• Electronic add-on items:

♦ A/C
♦ generator (alternators)
♦ engine turbo
♦ cellular telephone
♦ cruise control
♦ CB radio
♦ linear amplifiers
♦ backup alarm signal
♦ computer
• Vehicle modification.
• These items, if not installed correctly, will affect PCM or transmission function. Pay particular
attention to add-on wiring splices in the PCM harness or transmission wiring harness, abnormal tire
size or axle ratio changes.
• Leaks, refer to Leakage Inspection in this section.
Section 307-05A .
Selector Lever Linkage Check
Hydraulic leakage at the manual control valve can cause delay in engagements and/or slipping while operating
if the linkage is not correctly adjusted. Refer to Section 307-05A for selector lever linkage adjustment.
Check TSBs
Refer to all TSBs which pertain to the concern and follow the procedure.
Carry Out On-Board Diagnostics, Key ON Engine OFF (KOEO), Key ON Engine Running (KOER)
After a road test, with the engine and transmission at normal operating temperature and before disconnecting
any connectors, use the scan tool to perform the self-test procedure. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the powertrain control system.
Visual Inspection 3643

Visual Inspection 3644

Diagnostics
OBD with Scan Tool
These self-tests should be used to diagnose the TCM and should be carried out in order.
NOTE: Make sure to use the latest scan tool software release.
1. If the cause is not visually evident, connect the scan tool to the DLC .
NOTE: The VCM LED prove-out confirms power and ground from the DLC to the VCM .
2. If the scan tool does not communicate with the VCM :

• check the VCM connection to the vehicle.
• check the scan tool connection to the VCM .
• refer to Section 418-00 to diagnose no power to the scan tool.
3. If the scan tool does not communicate with the vehicle:

• verify the ignition is in the RUN position.
• verify scan tool operation with a known good vehicle.
• refer to Section 418-00 to diagnose no response from the TCM .
4. Carry out the network test.

• If the scan tool responds with no communication from one or more modules, refer to Section
418-00 .
• If the network test passes, retrieve and record the continuous memory DTCs.
5. Clear the continuous DTCs and carry out the TCM self-test.
6. If DTCs retrieved are related to the concern, GO to the DTC Chart.
7. If no DTCs related to the concern are retrieved, GO to Diagnosis By Symptom .
Diagnostics 3645
Diagnostics 3646
Output State Control (OSC) Mode
Special Tool(s)

Description
Output state control allows a diagnostic scan tool direct control of specific transmissiomponents or functions.
Output state control allows the technician to control the main functions or components of the transmission to
help the technician diagnose the transmission quickly and easily. For example, output state control may be
used to change gears or remain in a specific gear. Output state control may be used to control the operation of
the TCC to engage or disengage, or to keep the converter clutch from engaging at all. Output state control
may be used to help carry out solenoid electrical pinpoint tests by turning a solenoid off or on by controlling
the actual current to the VFS solenoid.
Procedure
NOTE: Retrieve Continuous Codes and carry out a KOEO and KOER On-Demand Self Test before using any
output state control. Any DTCs related to the TR sensor, the OSS sensor or the TSS sensor must be fixed or
the TCM will not allow the output state control to operate.
Output state control is used to test various transmission components and functions when the vehicle is in the
service bay or being driven on the road. Specific vehicle conditions are required for output state control to
control each specific function or component. The following describes which transmission functions and
components output state control may control and the specific vehicle conditions necessary for its operation.
Service Bay - Vehicle State No. 1
Vehicle state No. 1 is functional ONLY when the ignition is in the ON position and the selector lever is in
PARK or NEUTRAL with the engine OFF. Vehicle state No. 1 is required when using output state control to
carry out electrical pinpoint tests. The following transmission components may be controlled using output
state control in vehicle state No. 1.
• SSA_AMP - Controls the current to SSA , VFS

• SSB_AMP - Controls the current to SSB , VFS
• SSC_AMP - Controls the current to SSC , VFS SSD_AMP - Controls the current to SSD , VFS
• SSE - Directs TCM to command SSE OFF or ON
• LPC_AMP - Controls the current to the LPC VFS
• TCC_AMP - Controls the current to the TCC VFS
The vehicle requirements must be met when sending an output state control value to control each component
such as the solenoids stated above. If the vehicle requirements are not met when sending the output state
Output State Control (OSC) Mode 3647

control value, an error message may appear. When an error message appears, output state control is cancelled
and should be restarted.
After sending the output state control value, if the vehicle requirements are no longer met, the error message
will not appear but the output state control value will be cancelled by the TCM . Use the scan tool to monitor
the PID that corresponds to each output state control function or component to determine if the TCM is using
the output state control value or normal control.
Output state control may be cancelled at any time, to return the TCM to normal control for a specific output
state control function or component. See instructions for specific scan tool.
Service Bay - Vehicle State No. 2
Vehicle state No. 2 is functional ONLY when the engine is running and the selector lever is in PARK or
NEUTRAL with engine speed greater than 1,100 rpm. Vehicle state No. 2 is required when using output state
control to carry out a line pressure check. Most, but not all, of the solenoids may be controlled during this
vehicle state. It is recommended to use vehicle state No. 1 when using output state control to control the
solenoids. The following transmission function and components may be controlled using output state control
in vehicle state No. 2.
• LINEDSD - Output state control function to command line pressure to a desired pressure
• SSD_AMP - Controls the current to SSD , VFS
• SSC_AMP - Controls the current to SSC VFS
• SSB_AMP - Controls the current to SSB , VFS
• SSA_AMP - Controls the current to SSA , VFS
The vehicle requirements must be met when sending an output state control value to control each component
such as the solenoids stated above. If the vehicle requirements are not met when sending the output state
control value, an error message may appear. When an error message appears, output state control is cancelled
and should be restarted.
will not appear but the output state control value will be cancelled by the TCM . Use the scan tool to monitor
the PID that corresponds to each output state control function or component to determine if the TCM is using
the output state control value or normal control.
Output state control values for SSA_AMP, SSB_AMP, SSC_AMP, SSD_AMP, LPC_AMP and TCC_AMP
to control the current on the VFS solenoids are between zero (0) and one (1) amp. The following are
examples.
• 0 - Commands TCM to control current to zero amps

• 0.25 - Commands TCM to control current to 1/4 amp or 250 milliamps
• 1 - Commands TCM to control current to 1 amp or 1,000 milliamps
Output state control aids in testing the electronic functions of the TCM , VFS solenoid and associated
circuitry. Output state control allows the technician to control the TCM commanded current of the VFS
solenoids and the commanded state of the on/off solenoid. This allows the technician to accurately test the
electronic circuitry by comparing the commanded current with the actual current or the on/off state with the

actual voltage. Shifting the transmission through the various gears tests the mechanical operation of the VFS
solenoids. When using output state control to control the VFS current, the technician may measure the circuit
current using an inductive pickup or measure the circuit voltage drop to help verify the proper electrical
operation of each VFS solenoid.
The output state control values for LINEDSD to command a desired line pressure are between 414 kPa (60
psi) and 1,931 kPa (280 psi). The following are examples.
• 60 psi - Commands TCM to control line pressure to 414 kPa (60 psi)
• 200 psi - Commands TCM to control line pressure to 1,517 kPa (200 psi)
NOTICE: Do NOT command line pressure LOWER then 414 kPa (60 psi) or HIGHER then 1,931 kPa
(280 psi) or damage to the transmission can occur.
Output state control allows the technician to control the TCM commanded line pressure. This allows the
technician to accurately test the electronic pressure control system by comparing the output state control
commanded line pressure to the actual line pressure indicated on the pressure gauge. The pressure gauge
should be connected to the line pressure tap on the transmission. The PID corresponding to the commanded
line pressure must be monitored to make sure the TCM is using the output state control value for the
commanded line pressure. This test will help verify the correct operation of the transmission pump assembly,
pump regulator valve and the operation of the LPC solenoid.
Drive Test
Output state control allows control of 3 transmission functions while driving on the road.h transmission
function has a unique set of vehicle operating requirements that the technician is required to meet before the
TCM will allow output state control.
• TCC_OSC - Commands the TCM to engage or disengage the TCC

• GEAR_OSC - Commands the TCM to change gears (upshift or down-shift) or remain in a gear
• HRSH_SFT - Commands a slightly higher hydraulic pressure during engagements and upshifts
The vehicle requirements must be met when sending an output state control value to control the specific
functions stated above. If the vehicle requirements are not met when sending the output state control value, an
error message may appear. When an error message appears, output state control is cancelled and should be
restarted.
will not appear but the output state control value is cancelled by the TCM . Use the scan tool to monitor the
PID that corresponds to each output state control function or component to determine if the TCM is using the
outpte control value or normal control.
Drive Test - Torque Converter Clutch Control
The output state control values for TCC_OSC to engage or disengage the TCC are as follows:
• 0 - TCM in normal control of TCC and output state control is cancelled

• 1 or OFF - Commands TCM to keep the torque converter clutch from engaging
• 2 or ON - Commands TCM to engage the TCC using a normal ramp rate
• 3 or ON - Commands TCM to engage the TCC using a fast ramp rate
Controlling the TCC will assist the technician in testing the operation of the torque converter for engagements
and disengagements. Also, the technician may find it easier to evaluate upshifts and downshifts by first using
output state control to keep the TCC from engaging.
Vehicle requirements when using TCC_OSC - Controlling the TCC .
When SENDING the TCC_OSC value [1 or OFF], the engine must be running with the transmission in the
DRIVE position and the vehicle speed must be greater than 5 km/h (3 mph).
When SENDING the TCC_OSC value [2 or 3 or ON], the engine must be running with the selector lever in
the DRIVE position, transmission in 3rd, 4th, 5th or 6th gear, transmission temperature between 4°C (40°F)
and 121°C (250°F), the vehicle speed must be below 24 km/h (15 mph) and engine speed greater than 1,100
rpm with minimal engine load.
Drive Test - Upshift and Downshift Control
NOTE: Once output state control has successfully commanded the transmission to shift to the desired output
state control gear, the transmission will remain in that gear until output state control commands a different
gear or the vehicle conditions are no longer correct.
The output state control values for GEAR_OSC to control the transmission gear changes are as follows:
• 0 - TCM in normal shift control and output state control is cancelled

• 1 - Commands TCM to shift to 1st gear - no engine braking
• 2 - Commands TCM to shift to 2nd gear - with engine braking
• 3 - Commands TCM to shift to 3rd gear - with engine braking
• 4 - Commands TCM to shift to 4th gear - with engine braking
Controlling the gear changes will assist the technician in testing the various clutches and whether the
transmission is slipping in any particular gear. Output state control will command the TCM to upshift or
downshift depending on the output state control gear value the technician selects. The transmission will
remain in the output state control gear selected until another output state conor until output state control is
cancelled and/or the vehicle conditions for using output state control are no longer met.
Vehicle requirements when using GEAR_OSC - Controlling Gear Changes
When SENDING a GEAR_OSC value, the engine must be running with the selector lever in the DRIVE
position, and the vehicle speed must be greater than 5 km/h (3 mph).
Additional vehicle conditions required for upshifts:
• Vehicle speed must be greater then 32 km/h (20 mph) when commanding an upshift to 5th or 6th gear
Additional vehicle conditions required for downshifts:
• Vehicle speed must be less then 32 km/h (20 mph) when commanding a downshift to 1st gear
• Vehicle speed must be less then 64 km/h (40 mph) when commanding a downshift to 2nd gear

• Vehicle speed must be less then 97 km/h (60 mph) when commanding a downshift to 3rd gear
• Vehicle speed must be less then 129 km/h (80 mph) when commanding a downshift to 4th gear
• Vehicle speed must be less then 161 km/h (100 mph) when commanding a downshift to 5th gear
Drive Test - Pressure Added for Engagements and Upshifts
The output state control values for HRSH_SHFT to command a slight or moderate increase in hydraulic
pressure to test for harsh engagements and upshifts are as follows:
• 0 or OFF - TCM in normal pressure control for shifts and engagements and output state control is
cancelled
• 1 or ON - Commands TCM to moderately increase hydraulic pressure during engagements and
upshifts
Setting HRSH_SFT to 1 or ON allows the tn to moderately increase the pressure when performing
engagements such as P-R, P-D, N-R, N-D, R-D and when performing automatic upshifts. This can provide
additional diagnostic information to help the technician determine whether the electronic pressure control
system is providing at least limited control (a normal shift would become harsh). Using output state control to
control HRSH_SHFT [1 or ON] should make a softer engagement or shift more normal and an already normal
shift or engagement harsher by slightly increasing the pressure. This test should only be used to provide
additional diagnostic information and should not be the only scan tool or test to determine a faulty electronic
or hydraulic component.
Using Output State Control and Monitoring PIDs
To confirm that the output state control value was sent by the scan tool and the TCM has accepted the output
state control command, a corresponding PID for each output state control parameter must be monitored. After
SENDING the output state control value, the corresponding PID value should be the same as the output state
control value that was sent. Additional PIDs are listed that may be monitored to help the technician accurately
diagnose the transmission.
The following is a list of output state control parameters and their corresponding PIDs:
Output State Control Parameter Corresponding PID Additional PIDs

GEAR_OSC GEAR GEAR_RAT
HRSH_SHFT - GEAR, GEAR_RAT
LINEDSD LPC LPC_F
LPC_AMP LPC TCCRAT, TCCMCMD, TSLIP
SSA_AMP SSPCA SSPCA_F
SSB_AMP SSPCB SSPCB_F
SSC_AMP SSPCC SSPCC_F
SSD_AMP SSPCD SSPCD_F
TCC AMP TCC TCC_F, TCC_RAT
TCC_OSC TCC TCC_F, TCC_RAT


Diagnostic Parameters Identification (PID) Chart
Special Tool(s)

PID Name PID Description Units

GEAR PCM commanded transaxle gear P, R, N, 1, 2, 3, 4, 5
and 6
GEAR_OSC Output state control commanded gear P, R, N, 1, 2, 3, 4, 5
and 6
GEAR_RAT Transaxle gear ratio Ratio
HRSH_SHFT Output state control commanded firm shift On/Off
IN_GEAR PCM commanded transaxle gear P, R, N, 1, 2, 3, 4, 5
and 6
LINEDSD Output state control commanded line pressure Pressure
LPC PCM commanded pressure for the Line Pressure Control (LPC) Pressure
Variable Force Solenoid (VFS)
LPC AMP Output state control commanded current for the LPC VFS Amperes
LPC_F Fault status for the LPC VFS Fault/No Fault
OSS_F Fault status for Output Shaft Speed (OSS) sensor Fault/No Fault
OSS_SRC Actual speed of the OSS sensor (rpm) rpm
SSA_AMP Output state control commanded current for the Shift Solenoid A Amperes
(SSA)/CB1234 VFS
SSB_AMP Output state control commanded current for the Shift Solenoid B Amperes
(SSB)/C35R VFS
SSC_AMP Output state control commanded current for the Shift Solenoid C Amperes
(SSC)/CB26 VFS
SSD_AMP Output state control commanded current for the Shift Solenoid D Amperes
(SSD)/CBLR, C456 VFS
SSPCA PCM commanded pressure for the SSA /CB1234 VFS Pressure
SSPCA_F Fault status for the SSA /CB1234 VFS Fault/No Fault
SSPCB Commanded pressure for the SSB /C35R VFS Pressure
SSPCB_F Fault status for the SSB /C35R VFS Fault/No Fault
SSPCC PCM commanded pressure for the SSC /CB26 VFS Pressure
SSPCC_F Fault status for the SSC /CB26 VFS Fault/No Fault
SSPCD PCM commanded pressure for the SSD /CBLR, C456 VFS Pressure
SSPCD_F Fault status for the SSD /CBLR, C456 VFS Fault/No Fault
Diagnostic Parameters Identification (PID) Chart 3653

SSPCE_F Fault status for On/Off Shift Solenoid E (SSE)/CBLR, C456 VFS Fault/No Fault
TCC PCM commanded pressure for the Torque Converter Clutch (TCC) Pressure
VFS
TCC AMP Output state control commanded current for the TCC VFS Amperes
TCC_F Fault status for TCC VFS Fault/No Fault
TCC_OSC Output state control commanded pressure to the TCC VFS Pressure
TCC_RAT Actual speed ratio of torque converter (1.0 = fully engaged) Ratio
TCIL Transmission Control Indicator Lamp (TCIL) status On/Off
TCS_DEPRES Transmission Control Switch (TCS) status Depressed/Not
Depressed
TCS_STATE TCS status On/Off
TCC_SLIPACT Actual difference between engine speed and turbine speed, rpm
measured in rpm
TCC_SLIPDSD PCM commanded difference between engine speed and turbine rpm
speed, measured in rpm
TFT Transmission Fluid Temperature (TFT) Degrees
TFTV TFT voltage Voltage
TFT_F Fault status for TFT sensor Fault/No Fault
TR Transmission Range (TR) Range (P, R, N, D, L)
TRAN_RAT Actual transaxle gear ratio Ratio
TR_CRANK TR Range (P, R, N, D, L)
TR_DC TR Duty Cycle Frequency
TR_F Fault status for TR sensor Fault/No Fault
TR_FREQ TR Frequency Frequency
TSS_F Fault status for Turbine Shaft Speed (TSS) sensor Fault/No Fault
TSS_SRC Actual speed of the TSS sensor (rpm) rpm
Diagnostic Parameters Identification (PID) Chart 3654

Transaxle Drive Cycle Test
Special Tool(s)

After carrying out the self-test, use the followinansmission Drive Cycle Test for checking continuous codes:
NOTE: The Transmission Drive Cycle Test must be followed exactly. Malfunctions must occur 4 times
consecutively for the shift error DTC to be set. Torque converter failures must occur 5 times consecutively for
a continuous DTC to be set.
NOTE: When carrying out the Transmission Drive Cycle Test, see the Solenoid Operation Chart for correct
solenoid operation. Refer to Pinpoint Tests - OSC Equipped Vehicle .
1. Record then clear self-test DTCs.
2. Warm engine to normal operating temperature.
3. Make sure transmission fluid level is correct.
4. With transmission in DRIVE, moderately accelerate from stop to 80 km/h (50 mph). This allows the
transmission to shift into 6th gear. Hold speed and throttle opening steady for a minimum of 15
seconds.
5. With transmission in 6th gear and maintaining steady speed and throttle opening, lightly apply and
release the brake to operate the stoplamps. Hold speed and throttle steady for additional 5 seconds
minimum.
6. Brake to a stop and remain stopped for minimum of 20 seconds.
7. Repeat Steps 4 through 6 at least 5 times.
8. Carry out the self-test and record continuous codes.
• If DTCs are present, refer to Diagnostic Trouble Code (DTC) Charts . Service all non-transmission
DTCs first as they can directly affect the operation of the transmission. Repeat the self-test and road
test the vehicle to verify the correction. Clear the DTCs, carry out drive cycle and repeat the self-test
after completing service on the DTCs.
• If the self-test passes and a concern is still present, refer to Diagnosis By Symptom . Check TSBs for
diagnostic concern.
After OBD
Transaxle Drive Cycle Test 3655

NOTE: The vehicle wiring harness, TCM and non-transmission sensors may affect transmission operations.
Service these concerns first.
After the OBD procedures are complete, service all DTCs.
Begin with non-transmission related DTCs, then service any transmission related DTCs. Refer to the
Diagnostic Trouble Code (DTC) Charts for information on condition and symptoms. This chart is helpful
referring to the correct manual(s) and to aid in diagnosing internal transmission concerns and external
non-transmission inputs. The pinpoint tests are used in diagnosing electrical concerns of the transmission.
Make sure the vehicle wiring harness and TCM are diagnosed as well. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for diagnosing non-transmission electronic components. The
diagnostic routine hydraulic/mechanical charts will help in diagnosing internal transmission concerns and
external non-transmission inputs.
Before Pinpoint Tests
NOTE: Prior to entering pinpoint tests, check the TCM wiring harness for correct connections, bent or broken
terminals, corrosion, loose wires, correct routing, correct seals and their condition. Check the TCM , sensors
and actuators for damage. Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
NOTE: If a concern exists after the electrical diagnosis has been carried out, refer to Diagnosis By Symptom .
If DTCs appear while carrying out the OBD test, refer to the Diagnostic Trouble Code (DTC) Charts for the
appropriate repair procedure. Prior to entering pinpoint tests, refer to TSBs for transmission concerns.
Transaxle Drive Cycle Test 3656

Diagnostic Trouble Code (DTC) Charts
Special Tool(s)

DTC Chart
NOTE: Using a scan tool, retrieve DTCs. Begin with and repair all non-transmission related DTCs. Start with
the U-DTCs (communication link codes) and repair any transmission-related DTCs.
DTC Grouping Component H> Description Condition Symptom Action

P0657 - Transaxle Actuator supply Transaxle solenoid GO to
solenoid power voltage A power control • Harsh Pinpoint Test
control circuit/open provides power to all E.
engagements.
the solenoids. This • No
DTC sets if the voltage
transaxle solenoid to
power control relay solenoids.
circuit is open. • Maximum
line
pressure.
• Only
PARK,
REVERSE,
NEUTRAL
and 5th
gear
available.
• No
Torque
Converter
Clutch
(TCC).
• Poor
launch
due to
5th
gear
drive
away.
• Will
Diagnostic Trouble Code (DTC) Charts 3657

turn on
Malfunction
Indicator
Lamp
(MIL).
P0701 P2700 Transmission Transmission The PCM has detected Non-electrical
(Forward hydraulic and control system an intermittent clutch • Vehicle failure.
Clutch), clutch systems range/performance on fault and the decelerates
REPAIR the
P2701 (Direct (including control system keeps during more specific
Clutch), non-electrical getting stuck on ratio upshifts DTC first.
P2702 shift solenoid changes but when it or CLEAR the
(Intermediate faults, main turns off the suspected hangs DTCs. TEST
Clutch), control valve clutch it releases. No in gear the system for
P2703 body and stuck on DTCs s. • Will normal
(Low/Reverse clutch(s)). turn on operation. If
Clutch) and wrench the DTC
P2704 lamp. returns,
(Overdrive REFER to
Clutch) Diagnosis By
Symptom in
this section.
P0706 P1702, P1921 TR sensor TR sensor A circuit TR sensor frequency REPAIR the
range/performance. out of range. PCM • Possible more specific
receives a duty cycle no DTC first. GO
at 125 Hz. If the crank. to Pinpoint
frequency is out of • Only Test D .
range (75 to 175 Hz is PARK,
the acceptable range) REVERSE,
this DTC will set. NEUTRAL
Possible wiring, and 5th
connector or TR gear
sensor issue. available.
• Harsh
engagements.
• Extremely
delayed
engagements
(until a
DTC is
set).
• After a
DTC is
set and
the
high
side
opened.
♦ Harsh
engagements.
♦ Poor
performance
(due
to
a

5th
gear
drive
away).
♦ No
shifts.
• Will
turn on
MIL .
P0707 P1702, P1921 TR sensor TR sensor A circuit TR sensor circuit duty REPAIR the
low. cycle out of range, • Possible more specific
low. TR sensor duty no DTC first. GO
cycle below the crank. to Pinpoint
minimum value for • Only Test D .
park (possible open PARK,
circuit, short to REVERSE,
ground, wiring, NEUTRAL
connector or TR and 5th
sensor issue). gear
available.
• Harsh
engagements.
• Extremely
delayed
engagements
(until a
DTC is
set).
• After a
DTC is
set and
the
high
side
opened.
♦ Harsh
engagements.
♦ Poor
performance
(due
to
a
5th
gear
drive
away).
♦ No
shifts.
• Will
turn on
MIL .
P0708 P1702, P1921 TR sensor TR sensor A circuit TR sensor duty cycle REPAIR the
high. duty cycle out of • Possible more specific
range, high. Duty no DTC first. GO

cycle above the crank. to Pinpoint

maximum value for • Only Test D .
LOW (possible short PARK,
to power, wiring, REVERSE,
connector or TR NEUTRAL
sensor issue). and 5th
gear
available.
• Harsh
engagements.
• Extremely
delayed
engagements
(until a
DTC is
set).
• After a
DTC is
set and
the
high
side
opened.
♦ Harsh
engagements.
♦ Poor
performance
(due
to
a
5th
gear
drive
away).
♦ No
shifts.
• Will
turn on
MIL .
P0710 P0711, P0712, Transmission TFT sensor A REPAIR the
P0713 Fluid circuit • TFT sensor • TCC more specific
Temperature voltage input and DTC first. GO
(TFT) sensor too low or too stabilizedto Pinpoint
high. TFT shift Test B .
input schedule
indicates a may be
short to enabled
ground or an sooner
open circuit after
(could be a cold
wiring, start.
connector or • Harsh
sensor issue). or soft
shifts.

• Also see • Will

P0711, P0712 turn on
and P0713. wrench
lamp.
P0711 - TFT sensor TFT sensor A PCM has detected no GO to
circuit TFT sensor change • TCC Pinpoint Test
range/performance. during operation. and B.
stabilized
shift
schedule
may be
enabled
sooner
after a
cold
start.
• Harsh
or soft
shifts.
• Will
turn on
wrench
lamp.
P0712 P0710, P0712 TFT sensor TFT sensor A The PCM has detected REPAIR the
circuit low. a voltage drop across • TCC more specific
the TFT sensor and DTC first. GO
exceeds a temperature stabilizedto Pinpoint
greater than 171°C shift Test B .
(340°F) for more then schedule
2.5 seconds (grounded may be
circuit). enabled
sooner
after
cold
start.
• Harsh
or soft
shifts.
• Will
turn on
MIL .
P0713 P0710, P0713 TFT sensor TFT sensor A The PCM has detected REPAIR the
circuit high. a voltage drop across • TCC more specific
the TFT sensor and DTC first. GO
exceeds a temperature stabilizedto Pinpoint
less than -45°C shift Test B .
(-50°F) for more then schedule
2.5 seconds (open may be
circuit). enabled
sooner
after
cold
start.

• Harsh
or soft
shifts.
• Will
turn on
MIL .
P0715 P0717 Turbine Shaft TSS sensor A REPAIR the
Speed (TSS) circuit. • PCM has • Failure more specific
sensor detected TSS Mode DTC first. GO
sensor signal Effect to Pinpoint
failed to 0 Management
Test F .
speed when action
vehicle opens
conditions transaxle
(mainly solenoid
output speed) power
indicate TSS control
sensor output (removes
should be power
present. from
• Electrical all
failures (open, solenoids).
short) of the ♦ Provides
TSS sensor PARK,
wiring, REVERSE,
connector or a NEUTRAL
failure of the and
sensor itself 5th
will cause this gear
failure. with
maximum
line
pressure
and
open
TCC
available
(controlled
by
the
manual
lever).
• Harsh
engagements
(due to
maximum
line
pressure).
• Poor
launch
performance
(due to
5th
gear

drive
away).
• Will
turn on
MIL .
P0717 P0715 TSS sensor TSS sensor A REPAIR the
circuit no signal. • Non- MIL • Failure more specific
sister code to Mode DTC first. GO
P0715. Used Effect to Pinpoint
to illuminate Management
Test F .
the wrench action
light. opens
transaxle
solenoid
power
control
(removes
power
from
all
solenoids).
♦ Provides
PARK,
REVERSE,
NEUTRAL
and
5th
gear
with
maximum
line
pressure
and
open
TCC
available
(controlled
by
the
manual
lever).
• Harsh
engagements
(due to
maximum
line
pressure).
• Poor
launch
performance
(due to
5th
gear
drive

away).
P0718 - TSS sensor TSS sensor A PCM has detected an Will turn on GO to
circuit intermittent. erratic or noisy TSS wrench lamp. Pinpoint Test
sensor signal. F.
P0720 P0722 Output Shaft OSS sensor circuit. REPAIR the
Speed (OSS) • PCM has • Failure more specific
sensor detected OSS Mode DTC first. GO
Test C .
speed when action
vehicle opens
(mainly solenoid
turbine speed) power
indicate OSS control
should be power
present. from
• Electrical all
short) of the ♦ provides
OSS sensor PARK,
wiring, REVERSE,
failure of the and
OSS sensor 5th
itself will gear
cause this with
failure. maximum
line
pressure
and
open
TCC
available
(controlled
by
the
manual
lever).
• Harsh
engagements
(due to
maximum
line
pressure).
• Poor
launch
performance
(due to
5th
drive
away).

• Will
turn on
MIL .
P0721 - OSS sensor OSS sensor circuit PCM has detected an Will turn on GO to
range/performance. erratic or noisy OSS wrench lamp. Pinpoint Test
sensor signal. C.
P0722 P0720 OSS sensor OSS sensor circuit REPAIR the
no signal. • Non- MIL • Failure more specific
sister code to Mode DTC first. GO
P0720. Used Effect to Pinpoint
to illuminate Management
Test C .
the wrench action
light. opens
transaxle
solenoid
power
control
(removes
power
from
all
solenoids).
♦ Provides
PARK,
REVERSE,
NEUTRAL
and
5th
gear
with
maximum
line
pressure
and
open
TCC
available
(controlled
by
the
manual
lever).
• Harsh
engagements
(due to
maximum
line
pressure).
• Poor
launch
performance
(due to
5th
gear

drive
away).
P0729 - Transaxle Gear 6 incorrect The PCM did not Intermediate
ratio detect a 6th gear ratio. • Customer(2,6) clutch or
may overdrive
• Shift Solenoid notice (4,5,6) clutch
C (SSC) flares slip or failed
and/or Shift or to apply.
Solenoid D neutral REFER to the
(SSD) stuck conditionsClutch
off on Application
non-electrical shifts. chart located
fault (no • Erratic in
pressure). shifting, Specifications
• Low/reverse flares, in this section.
clutch and/or neutral CLEAR the
overdrive conditionsDTCs. TEST
clutch while the system for
regulator the normal
valve stuck in code is operation. If
default being the DTC
position. set. returns,
• Low/reverse • 6th REFER to
clutch and/or gear Diagnosis By
overdrive disabled.Symptom in
clutch boost • Will this section.
valve stuck in turn on
default MIL .
position. • TCIL
flashing
• Will
turn on
wrench
lamp.
P0731 - Transaxle Gear 1 incorrect Forward
ratio • Forward • Customer(1,2,3,4)
clutch, might clutch,
low/reverse notice low/reverse
clutch or flares (L,R) clutch or
One-Way or OWC slip or
Clutch neutral failed to
(OWC) failed apply. REFER
conditions,
to apply. hangs to the Clutch
• Shift Solenoid in gear. Application
A (A) and/or • Disable chart located
SSD stuck off 1st in
non-electrical gear. Specifications
fault (no • No in this section.
pressure). engine CLEAR the
• Forward braking. DTCs. TEST
clutch and/or • Will the system for
low/reverse turn on normal
clutch wrench operation. If
regulator lamp. the DTC

valve stuck in returns,

default REFER to
position. Diagnosis By
• Forward Symptom in
clutch and/or this section.
low/reverse
clutch boost
valve stuck in
default
position.
clutch or might clutch, or
intermediate notice intermediate
clutch failed flares (2,6) clutch
to apply. or failed to
• SSA and/or neutral apply. REFER
SSC stuck off conditions,
to the Clutch
non-electrical hangs Application
fault (no in gear. chart located
presse). • Disable in
• Forward 2nd Specifications
clutch and/or gear. in this section.
intermediate • Will CLEAR the
clutch turn on DTCs. TEST
regulator wrench the system for
valve stuck in lamp. normal
default operation. If
position. the DTC
• Forward returns,
clutch and/or REFER to
intermediate Diagnosis By
clutch boost Symptom in
valve stuck in this section.
default
position.
direct clutch notice direct (3,5,R)
failed to flares clutch failed to
apply. or apply. REFER
• SSA and/or neutral to the Ctch
Shift Solenoid conditions,
Application
B (SSB) stuck hangs chart located
off in gear. in
non-electrical • Disable Specifications
fault (no 3rd in this section.
pressure). gear. CLEAR the
• Forward • Will DTCs. TEST
clutch and/or turn on the system for
direct clutch wrench normal
regulator lamp. operation. If
valve stuck in the DTC

default returns,
position. REFER to
• Forward Diagnosis By
clutch and/or Symptom in
direct clutch this section.
boost valve
stuck in
default
position.
overdrive notice overdrive
clutch failed flares (4,5,6) clutch
to apply. or failed to
• SSA and/or neutral apply. REFER
SSD stuck off conditions,
to the Clutch
non-electrical hangs Application
fault (no in gear. chart located
pressure). • Disable in
• Forward 4th Specifications
clutch and/or gear. in this section.
overdrive • Will CLEAR the
clutch turn on DTCs. TEST
regulator wrench the system for
valve stuck in lamp. normal
default operation. If
position. the DTC
• Forward returns,
clutch and/or REFER to
overdrive Diagnosis By
clutch boost Symptom in
valve stuck in this section.
default
position.
P0735 - Transaxle Gear 5 incorrect Direct (3,5,R)
ratio • Direct clutch • Customerclutch, or
or overdrive might overdrive
clutch failed notice (4,5,6) clutch
to apply. flares failed to
• SSB and/or or apply. REFER
SSD stuck off neutral to the Clutch
non-electrical conditions,
Application
fault (no hangs chart located
pressure). in gear. in
• Direct clutch, • Disable Specifications
low/reverse 5th in this section.
clutch and/or gear. CLEAR the
overdrive • Will DTCs. TEST
regulator turn on the system for
valve stuck in wrench normal
default lamp. operation. If
position. the DTC
returns,

• Low/reverse REFER to
clutch and/or Diagnosis By
overdrive Symptom in
clutch boost this section.
valve stuck in
default
position.
P0740 P0743 TCC TCC solenoid Open circuit. GO to
circuit open • TCC Pinpoint Test
failed A .
off.
• Will
turn on
MIL .
• TCIL
flashing
P0741 P0748 TCC TCC solenoid TCC mechanically DTC P0741 is
circuit stuck off. a
• Non-electrical
performance/stuck TCC non-electrical
off. solenoid DTC. CLEAR
stuck the DTCs.
off. TEST the
• TCC system for
normal
mechanical
failure. operation. If
• TCC the DTC
regulatorreturns,
apply REFER to
valve Torque
stuck in Converter
release Operation
position.Concerns, No
• TCC Apply in
control Diagnosis By
valve Symptom in
stuck in this section.
release
position.
• TCC
failed
to
apply
(less
than 80
rpm
slip
error
lasting
at least
3
seconds
when
TCC is

commanded
on) 3
consecutive
times.
• Will
turn on
MIL .
• TCIL
flashing
P0742 P0743 TCC TCC solenoid Circuit shorted to REPAIR the
circuit stuck on. ground, TCC failed • Failure more specific
on. Mode DTC first. GO
Effect to Pinpoint
Management
Test A .
action
opens
the
transaxle
solenoid
power
control,
removing
power
from
all
solenoids
(get
PARK,
REVERSE,
NEUTRAL
and 5th
gear as
the
only
forward
gear
with
TCC
open).
• Harsh
engagements.
• Poor
launch
performance
(due to
5th
gear
drive
away).
• No
TCC
apply.
• No
shifts.

• Will
turn on
MIL .
• TCIL
flashing
P0743 P0740, P0742 TCC TCC solenoid Sister code to P0740, REPAIR the
or P0744 circuit electrical. P0742 or P0744 used • Will more specific
to illuminate the turn on DTC first. GO
wrench light. wrench to Pinpoint
lamp. Test A .
• TCIL
flashing
P0744 P0743 TCC TCC solenoid Circuit short to power. REPAIR the
circuit intermittent. • TCC more specific
failed DTC first. GO
off. to Pinpoint
• Will Test A .
turn on
MIL .
• TCIL
flashing
P0748 P0960, P0962 Line Pressure LPC electrical. LPC circuit failure REPAIR the
and P0963 Control (LPC) non- MIL . Sister code • Failure more specific
to P0960, P0962 and Mode DTC first. GO
P0963 used to Effect to Pinpoint
illuminate the wrench Test A .
Management
light. Additional action,
common fault DTCs, see
P0750, P0751, P0752. DTCs
P0960,
P0962
and
P0963.
• Will
turn on
wrench
lamp.
• TCIL
flashing
P0750 P0751 Shift Solenoid A SSA Open circuit. REPAIR the
(SSA) • Customermore specific
might DTC first. GO
notice a to Pinpoint
neutral Test A .
condition,
or a
single
erratic
or
unexpected
shift.
• 5th and
6th

gears
only.
• Poor
launch
due to
5th
gear
drive
away.
• Will
turn on
MIL .
P0751 P2700 Forward clutch SSA Forward (1,2,3,4) REFER to
performance/stuck clutch failed to apply • CustomerDiagnosis By
off. when commanded. may Symptom in
notice this section.
• SSA neutral
non-electrical conditions
failed stuck or
off (no flares
pressure). on
• Forward downshifts
clutch stuck from
off due to 5th or
mechanical 6th
failure. gear.
• Forward • Once
clutch the
regulator DTC is
valve stuck in stored,
the default gears 1
position. through
• Forward 4 are
clutch boost disabled
valve stuck in -
the default leaving
position. 5th and
6th
gears
as the
only
forward
gears.
• Erratic
shifting,
harsh
engagements,
neutral
conditions,
flares,
poor
launch
performance,
harsh

reverse
engagements.
• Will
turn on
MIL .
P0752 - SSA SSA stuck o Forward (1,2,3,4) REFER to
clutch failed to release • CustomerDiagnosis By
when commanded. may Symptom in
notice a this section.
• SSA vehicle
non-electrical deceleration
failed stuck on a
on (pressure). shift
• Forward into 5th
clutch stuck or 6th
on due to gear
mechanical (forward
failure. clutch
• Forward failing
clutch to
regulator release
valve stuck in will
the spring cause a
compressed tie-up
position. in 5th
or 6th
gear).
• Customer
might
notice
erratic
shifting
or
being
stuck in
4th
gear.
• Once
the
DTC is
stored,
5th and
6th
gears
are
disabled.
• Will
turn on
MIL .
P0753 P0750, P0973 SSA SSA electrical. Sister code to P0750, REPAIR the
and P0974 P0973 and P0974 • Failure more specific
used to illuminate the Mode DTC first. GO
wrench light. Effect to Pinpoint
Additional common Management
Test A .

fault DTCs, P0752, action,

P0754, P0755. see
DTCs
P0750,
P0973
and
P0974.
• Will
turn on
wrench
lamp.
P0754 - SSA SSA intermittent. Intermittent SSA GO to
circuit faults but not • CustomerPinpoint Test
lasting long enough to might A .
trip DTC, P0750, notice
P0973 or P0974. unexpected
upshifts,
downshifts,
flairs or
neutral
conditions.
• Will
turn on
wrench
lamp.
P0755 P0756 SSB SSB . Open circuit or short REPAIR the
to power. • Customermore specific
might DTC first. GO
notice to Pinpoint
unexpectedTest A .
upshift.
• 3rd and
5th
gears
available.
• Harsh
engagements.
• Poor
launch
performance.
• Will
turn on
MIL .
P0756 P2701 Direct clutch SSB Direct (3,5,R) clutch REFER to
performance/stuck failed off • CustomerDiagnosis By
off. may Symptom in
• Non-electrical notice this section.
failures where flares
SSB direct or
clutch is stuck neutral
off (no conditions
pressure). on
• Direct clutch shifts
regulator into 3rd

valve stuck in or 5th

default gear.
position. • PCM
• Direct clutch will
mechanical command
failure. 3 shifts
into 3rd
or 5th
gear,
and if
direct
clutch
is
failed
off the
customer
will
notice
flares
or
neutral
conditions
that last
one
second
or so.
• 3rd and
5th
gears
are
disabled,
customer
might
notice
transmission
hangs
in 2nd
on
acceleration
until
customer
tips out
to
closed
pedal
(done
to
protect
overdrive
clutch).
• Will
turn on
MIL .
P0757 P2701 SSB SSB stuck on.

SSB (direct clutch) • CustomerREFER to

failed on, causing may Diagnosis By
direct clutch failed on. notice a Symptom in
vehicle this section.
Since the hydraulic deceleration
controls prevent direct on a
clutch and low/reverse shift
clutch on together in into
the forward ranges we 2nd,
can isolate the 4th or
solenoid from the 6th
clutch. gear.
• Harsh
This code sets if: 1-3
shift.
• Non-electrical • Poor
failures where launch
SSB (direct performance
clutch) is lack of
stuck on shifts.
(pressure). • Will
• Direct clutch turn on
regulator MIL .
valve stuck in
spring
compress
position.
P0758 P0755, P0976 SSB SSB electrical. Sister code to P0755, REPAIR the
Additional common ManagementTest A .
fault DTCs, P0755, action
P0976, P0977. see
P0755,
P0976
and
P0977.
• Will
turn on
wrench
lamp.
P0759 - SSB SSB intermittent. Intermittent SSB GO to
P0758, P0976 or unexpected
P0977. upshifts,
downshifts,
flairs or
neutral
conditions.
• Will
turn on

wrench
lamp.
P0760 P0761 SSC SSC . Open circuit. REPAIR the
• Customermore specific
might DTC first. GO
notice to Pinpoint
erratic, Test A .
delayed
or
harsh
shifts.
• Disable
2nd
and 6th
gears.
• Will rn
on MIL
.
P0761 P2702 Intermediate SSC Intermediate clutch REPAIR the
clutch performance/stuck failed off • Customermore specific
off. may DTC first.
• Non-electrical notice REFER to
failures where neutral Diagnosis By
SSC conditionsSymptom in
intermediate or this section.
clutch is stuck flares
off (no on
pressure). shifts
• Intermediate to 2nd
clutch stuck or 6th
off due to gear.
mechanical • Disabled
failure. 2nd
• Intermediate and 6th
clutch gears.
regulator • Erratic
valve stuck in shifting,
the default neutral
position. conditions,
flares,
higher
engine
speeds
on
highway
due to
6th
gear
being
disabled.
• Will
turn on
MIL .
P0762 P0763 SSC SSC stuck on.

Intermediate clutch • CustomerREPAIR the

failed on, could be may more specific
due to: notice a DTC first.
vehicle REFER to
• Intermediate deceleration
Diagnosis By
clutch SSC on a Symptom in
non-electrical shift this section.
failed stuck into 3rd
on (pressure). or 5th
• Intermediate gear
clutch stuck (intermediate
on due to clutch
mechanical failing
failure. to
• Intermediate release
clutch will
regulator cause a
valve stuck in tie-up
the spring in 3rd
compressed or 5th
position. gear).
• Erratic
shifting
or
being
stuck in
6th
gear.
• 3rd, 4th
and 5th
gears
are
disabled.
• Hangs
in 2nd
gear on
acceleration
since
2nd-6th
upshifts
only
occur
at
closed
pedal
(due to
energy
limitations
of
overdrive
clutch),
harsh
reverse
engagements

(since
low/reverse
clutch
is not
on in
2nd
gear).
• Will
turn on
MIL .
P0763 P0760, P0979 SSC SSC electrical. Sister code to P0760, REPAIR the
Additional common ManagementTest A .
P0976, P0977. see
P0760,
P0979
and
P0980.
• Will
turn on
wrench
lamp.
P0764 - SSC SSC intermittent. Intermittent SSC GO to
P0979 and P0980. unexpected
upshifts,
downshifts,
flairs or
neutral
conditions.
• Will
turn on
wrench
lamp.
P0765 P0766 SSD SSD . Open circuit. REPAIR the
• Overdrive more specific
clutch DTC first. GO
failed to Pinpoint
on, Test A .
only
4th, 5th
and 6th
gears
available.
• Harsh
engagements.
• Poor
launch
due to

4th
gear
drive
away.
• Will
turn on
MIL .
P0766 P2704 Overdrive clutch SSD performance Overdrive clutch REPAIR the
system fault stuck off. failed off. • Customermore specific
includes may DTC first.
non-electrical • Non-electrical notice REFER to
SSD fault, main failure where flares Diagnosis By
control valve SSD , or Symptom in
body and clutch low/reverse neutral this section.
and overdrive conditions
clutch is stuck on
off (no shifts
pressure). into
• Low/reverse 4th, 5th
clutch/overdrive or 6th
clutch gear.
regulator • Erratic
valve stuck in shifting,
default flares,
position. neutral
• Low/reverse conditions
clutch/overdrive while
clutch boost the
valve stuck in code is
default being
position. set.
• 1st,
4th, 5th
and 6th
gears
are
disabled
- may
notice
high
engine
rpm
since
3rd is
highest
available
gear.
• May
get
delayed
or no
reverse
engagement
(need

low/reverse
clutch
on to
achieve
reverse).
• Will
turn on
MIL .
P0767 P07A9, P2704 Overdrive or SSD stuck on. Overdrive clutch REPAIR the
low/reverse failed on, could be • Customermore specific
clutch due to: may DTC first.
notice REFER to
• Low/reverse vehicle Diagnosis By
or overdrive deceleration
Symptom in
clutch SSD on this section.
non-electrical shifts
failed stuck into
on (pressure). 2nd or
• Overdrive 3rd
clutch stuck gear
on due to (overdrive
mechanical clutch
failure. failing
• Low/reverse, to
overdrive release
clutch will
regulator cause a
valve stuck in tie-up
the in 2nd
spring-compressed or 3rd
position. gear).
• 1st, 2nd
and 3rd
gears
are
disabled.
• Poor
launch
due to
4th
gear
drive
away.
• Harsh
engagements.
• Will
turn on
MIL .
P0768 P0765, P0982 SSD SSD electrical Sister code to P0765, REPAIR the
Additional common Management
Test A .

P0769, P0770. see

P0765,
P0982
and
P0983.
• Will
turn on
wrench
lamp.
P0769 - SSD SSD intermittent. Intermittent SSD
circuit faults but not • Customer
lasting long enough to might
P0768, P0982 and unexpected
P0983. upshifts,
GO to
downshifts,
Pinpoint Test
flairs or
A.
neutral
conditions.
• Will
turn on
wrench
lamp.
P0770 P0773 Shift Solenoid E SSE . Open, short to ground SSE failed off REPAIR the
(SSE) or short to power. (no pressure): more specific
DTC first. GO
• Customerto Pinpoint
might Test A .
notice
4th
gear
drive
away
when
1st gear
is
commanded.
• Failed
off (no
pressure)
then 1st
gear
with
engine
braking
is
disabled.
• May or
may
not
notice
2nd
gear
provided

when
1st gear
selected
in low
manual
range.
• Harsh
reverse
engagements
since
low/reverse
clutch
does
not
apply
in
neutral
or drive
in this
failure
mode.
SSE failed on
(pressure):
• High
side is
turned
off.
• Poor
launch
performance
due to
5th
gear
drive
away.
• Harsh
engagements.
• No
TCC
apply.
• Will
turn on
MIL .
P0771 P0984 SSE failed off SSE REPAIR the
performance/stuck • SSE controls • If SSE more specific
off. the is DTC first. GO
multiplexing failed to Pinpoint
of SSD off or Test A .
low/reverse valve 2
and overdrive is stuck
clutch. If in
solenoid fails default

off (no position

pressure) then then
1st gear is the
failed to 4th customer
gear. will get
• If clutch 4th
select valve 2 gear
sticks in the when
default 1st gear
position then is
1st gear with selected.
engine • Will
braking is turn on
failed to 4th wrench
gear and lamp.
reverse is
failed to
neutral.
• The
diagnostic
does not
distinguish
SSE stuck off
from valve 2
stuck in
default. This
code means
either:
♦ SSE
short
to
power,
failed
off
(no
pressure).
♦ Valve
2
stuck
in
default
position.
P0772 P0984 SSE failed on SSE stuck on. REPAIR the
• SSE controls • If SSE more specific
the is DTC first. GO
multiplexing failed to Pinpoint
of SSD on or Test A .
low/reverse valve 2
and overdrive is stuck
clutch. If the in
solenoid fails spring
on (pressure) compressed
then, 1st and position,
2nd gear are then 1st

the only and

available 2nd
gears. 3rd gears
gear is failed are the
to 1st gear, only
4th gear is available
failed to 1st gears.
gear, 5th gear • Customer
is failed to might
neutral, and notice
6th gear is a flares
tie-up. on
• If clutch shifts
select valve 2 into 3rd
sticks in the gear.
spring-compressed Deceleration
position, the on
same ratio shifts
pattern will into 4th
occur. This gear
code means since
either: you get
♦ SSE 1st gear
short or a
to neutral
ground, condition
failed on
on shifts
(pressure). into 5th
♦ Valve gear.
2 High
stuck engine
in rpm
spring since
compressed 2nd
position. gear is
top
available
gear.
• Will
turn on
wrench
lamp.
P0773 P0770 SSE SSE electrical. Open, short to ground Sister code to GO to
or short to power in P0770 used to Pinpoint Test
solenoid or wiring. illuminate the A .
wrench light.
• Failure
Mode
Effect
Management
action
see

P0770.
• Will
turn on
wrench
lamp.
P0774 - SSE SSE intermittent. Intermittent SSD GO to
circuit faults but not • Failure Pinpoint Test
lasting long enough to Mode A .
trip DTC, P0770. Effect
Management
action
see
P0770.
• Will
turn on
wrench
lamp.
P07A5 - Direct clutch Transmission direct Ratio based test. The REFER to
clutch stuck on. clutch control bypass • CustomerDiagnosis By
valve (multiplex may Symptom in
valve) exhausts the notice this section.
direct clutch when the slow
valve is in the acceleration
compressed position, from
where SSD points in stop.
the low/reverse May be
position, the in 3rd
diagnostic can isolate gear
the direct clutch stuck when
on from SSB stuck on 1st gear
because getting 3rd is
gear in 1st when the commanded.
clutch control bypass • Once
valve is in the spring the
compressed position DTC is
indicates that SSB stored,
cannot be the cause. 3rd and
5th
gears
are
only
available.
• Erratic
shifting,
harsh
engagements,
poor
launch
performance.
• Will
turn on
wrench
lamp.
P07A8 -

Low/reverse Transmission SSD is multiplexed • CustomerREFER to

clutch low/reverse clutch through the clutch may Diagnosis By
performance/stuck control bypass valve notice Symptom in
off. (multiplex valve) to no this section.
the low/reverse and reverse.
overdrive clutch, the • Disable
diagnostic can isolate 1st
the low/reverse clutch gear.
failed off from SSD • Delayed
stuck off when the engagement
overdrive clutch into
applies normally and drive.
the low/reverse clutch • Poor
did not. launch
performance
due to
2nd
gear
launch.
• Will
turn on
wrench
lamp.
P07A9 P0767 Low/reverse Transmission SSD is multiplexed REFER to
clutch low/reverse clutch through the clutch Diagnosis By
• Low/reverse
stuck on. control bypass valve clutch Symptom in
(multiplex valve) to failed this section.
the low/reverse and on.
overdrive clutch, the • One-Way
diagnostic can isolate Clutch
the low/reverse stuck (OWC)
on by turning off SSE transmits
. If the transaxle shifts torque
into 4th when the in both
clutch control bypass directions.
valve moves SSD is • Stuck
stuck on, but if the in 1st
transaxle stays in 1st gear.
then the low/revers is • Will
stuck on. turn on
wrench
lamp.
P07AA - Overdrive clutch Transmission SSD is multiplexed REFER to
overdrive clutch through the clutch • OverdriveDiagnosis By
performance/stuck control bypass valve clutch Symptom in
off. (multiplex valve) failed this section.
between the off.
low/reverse and • Disable
overdrive clutch, the 4th, 5th
diagnostic can isolate and 6th
the overdrive clutch gears.
failed off from SSD • Reverse
stuck off when the may be
low/reverse clutch delayed

applies normally but or

the overdrive clutch is disabled.
stuck off. • High
engine
rpm.
• Will
turn on
wrench
lamp.
P0815 - Upshift switch The associated REFER to
circuit circuitry to and from • SelectSwtchTM
Section
SelectSwtchTM the SelectSwtchTM upshift 307-05A .
upshift switch switch, fuse or the inoperative.
output circuit SelectSwtchTM • Will
failure switch itself may have turn on
an open or is shorted wrench
to ground. lamp.
P0816 - Downshift SelectSwtchTM The associated REFER to
switch circuit downshift switch circuitry to and from Section
• SelectSwtchTM
output circuit the SelectSwtchTM downshift307-05A .
failure switch, fuse or the inoperative.
SelectSwtchTM • Will
switch itself may have turn on
an open or is shorted wrench
to ground. lamp.
P0867 - Transmission Transmission fluid The control valve test REFER to
hydraulic and pressure. raissure to insure that • MultiplexDiagnosis By
clutch systems the clutch control latch Symptom in
bypass valve pressure this section.
(multiplex valve) is inadequate
latched, then turns on (valve
SSE to test for a stuck moves
TCC control valve when
under steady state SSE
operation in 4th, 5th turns
and 6th gear. If the on).
ratio breaks away the • Overdrive
test is aborted. If clutch
enough ratio break pressure
away occur, the DTC issue.
is set. • Line
pressure
issues.
• Solenoid
regulator
valve
issues.
• Customer
may
notice
flairs
during
test.

• Will
turn on
wrench
lamp.
P0960 P0748 LPC LPC control LPC circuit has failed REPAIR the
circuit/open. to 0 current. • Failed more specific
to DTC first. GO
maximum to Pinpoint
line Test A .
pressure.
• Harsh
engagements.
• Will
turn on
MIL .
P0961 P0748 LPC LPC control circuit Intermittent LPC short GO to
range/performance. to ground. Fault • Harsh Pinpoint Test
present long enough engagement
A.
to notice a neutral and
condition (minimum harsh
pressure) but not shifts.
present long enough • Will
to store a DTC. turn on
wrench
lamp.
P0962 P0748 LPC LPC control circuit LPC short to ground Failed to 0 REPAIR the
low. circuit failure. current, more specific
minimum line DTC first. GO
pressure: to Pinpoint
Test A .
• Failure
Mode
Effect
Management
action
opens
the
transaxle
solenoid
power
control
relay,
removing
power
from
all
solenoids
which
provides
maximum
line
pressure.
• Harsh
engagements.

• Poor
launch
performance
(due to
5th
gear
drive
away).
• No
TCC
apply.
• No
shifts.
• Will
turn on
MIL .
P0963 P0748 LPC LPC control circuit LPC short to power Failed to 0 REPAIR the
high. circuit fault. current, more specific
maximum line DTC first. GO
pressure: to Pinpoint
Test A .
• Harsh
engagements.
• Will
turn on
MIL .
P0973 P0753 SSA SSA control circuit Short to ground. REPAIR the
low. • Failure more specific
Mode DTC first. GO
Effect to Pinpoint
Test A .
Management
action
opens
the
transaxle
solenoid
power
control
relay,
removing
power
from
all
solenoids
(get
PARK,
REVERSE,
NEUTRAL
and 5th
gear as
the
only
forward
gear

with
TCC
open).
• Harsh
engagements.
• Poor
launch
performance
(due to
5th
gear
drive
away).
• No
TCC
apply.
• No
shifts.
• Will
turn on
MIL .
P0974 P0753 SSA SSA control circuit Short to power. REPAIR the
high. • Forward more specific
is to Pinpoint
failed Test A .
off -
5th and
6th
gears
only
available
forward
gears.
• Neutral
condition
or flare
when
fault
occurs.
• Poor
launch
due to
5th
gear
drive
away
• Will
turn on
MIL
P0976 P0758 SSB SSB control circuit Short to ground. REPAIR the
Mode DTC first. GO
Effect to Pinpoint

Management
Test A .
action
opens
the
transaxle
solenoid
power
control
relay,
removing
power
from
all
solenoids
(get
PARK,
REVERSE,
NEUTRAL
and 5th
gear as
the
only
forward
gear
with
TCC
open).
• Harsh
engagements.
• Poor
launch
performance
(due to
5th
gear
drive
away).
• No
TCC
apply.
• No
shifts.
• Will
turn on
MIL .
P0977 P0758 SSB SSB control circuit Short to power. REPAIR the
high. • Direct more specific
failed to Pinpoint
on - Test A .
only
3rd and
5th
gears

available.
• Harsh
1-3
shift if
failure
occurs
while
in 1st.
• Poor
launch
due to
3rd
gear
drive
away.
• Will
turn on
MIL .
P0979 P0763 SSC SSC control circuit ort to ground. REPAIR the
Mode DTC first. GO
Effect to Pinpoint
Test A .
Management
action
opens
the
transaxle
solenoid
power
control
relay,
removing
power
from
all
solenoids
(get
PARK,
REVERSE,
NEUTRAL
and 5th
gear as
the
only
forward
gear
with
TCC
open).
• Harsh
engagements.
• Poor
launch
performance

(due to
5th
gear
drive
away).
• No
TCC
apply.
• No
shifts.
• Will
turn on
MIL .
P0980 P0763 SSC SSC control circuit Open circuit. REPAIR the
high. • If fault more specific
occurs DTC first. GO
while to Pinpoint
in 2nd Test A .
or 6th
gear,
customer
might
notice a
neutral
condition
before
diagnostics
disables
2nd
and 6th
gears.
• Erratic,
delayed
or
harsh
shifts.
• Will
turn on
MIL .
P0982 P0768 SSD SSD control circuit Short to ground. REPAIR the
Mode DTC first. GO
Effect to Pinpoint
Management
Test A .
action
opens
the
transaxle
solenoid
power
control
relay,
removing
power

from
all
solenoids
(get
PARK,
REVERSE,
NEUTRAL
and 5th
as the
only
forward
gear
with
TCC
open),
harsh
engagements.
• Poor
launch
performance
(due to
5th
gear
drive
away).
• No
TCC
apply.
• No
shifts.
• Will
turn on
MIL .
P0983 P0768 SSD SSD control circuit Open circuit. REPAIR the
high. • Only more specific
4th, 5th DTC first. GO
and 6th to Pinpoint
gears Test A .
available.
• Harsh
engagements.
• Poor
launch
due to
4th
gear
drive
away.
• Will
turn on
MIL .
P0984 P0771, P0772 SSE SSE control circuit This DTC sets with REPAIR the
range/performance. either P0771 or • Will more specific
P0772. turn on DTC first. GO

wrench to Pinpoint
lamp. Test A .
P1500 P0722 VSS sensor OSS sensor circuit. REPAIR the
• PCM has • Failure more specific
detected VSS Mode DTC first. GO
Test C .
speed when action
vehicle opens
(mainly solenoid
turbine speed) power
indicate OSS control
should be power
present. from
• Electrical all
short) of the ♦ provides
OSS sensor PARK,
wiring, REVERSE,
failure of the AND
OSS sensor 5th
itself will gear
cause this with
failure. maximum
line
pressure
and
open
TCC
available
(controlled
by
the
manual
lever).
• Harsh
engagements
(due to
maximum
line
pressure).
• Poor
launch
performance
(due to
5th
drive
away).
• Will
turn on
MIL .

P1636 - PCM Inductive signature Lost communication • Traaxle INSTALL a

chip with solenoid driver. solenoid new PCM.
communication power REFER to
error. • The solenoid control Section
driver is an relay 303-14A or
internal PCM turned Section
chip that off, 303-14B .
controls the providing
solenoids. The PARK,
main REVERSE,
microchip NEUTRAL
communicates and 5th
with the gear
solenoid with
driver over a TCC
serial open
interface, and
sending out maximum
the desired line
solenoid state pressure.
and receiving • Harsh
back a circuit engagements.
fault status. • Poor
• If performance
communication launch
is lost with (due to
the solenoid 5th
driver, the drive
solenoid away).
states become • No
unknown, so TCC
the control apply.
system forces • No
the transaxle shifts.
solenoid • Will
power control turn on
relay off. MIL .
P163E - TRID block Transmission REFER to
control module • TRID version • CostumerSolenoid Body
programming error. incorrect may Strategy in
(TRID notice, this section.
version does high
not match engine
version in rpm.
PCM • 1st and
Calibration). 3rd
• 7-digit service gear
banding code only.
checksum or • No
total TRID TCC
block apply.
checksum • Will
invalid. turn on
MIL .

• Solenoid and
Clutch
characterization
data
unavailable.
• Failure Me
Effect
Management
will increase
pressure and
allow only
PARK,
REVERSE,
NEUTRAL,
1st and 3rd
gear only.
P163F - TRID block TRID ID block
corrupted, not • TRID data not • Failure
programmed. programmed. Mode
• Solenoid and Effect
Clutch Management
strategy data action
unavailable. of
• Failure Mode limits
Effect function
Management to 1st
will increase and 3rd REFER to
pressure and gear. Solenoid Body
allow only • High Strategy in
PARK, engine this section.
REVERSE, rpm,
NEUTRAL, lack of
1st and 3rd shifts
only. complaints.
• No
TCC
apply.
• Will
turn on
MIL .
P1702 P0706, P0707 TR sensor TR sensor circuit Sister code to P0706 REPAIR the
and P0708 intermittent. P0707 and P0708 • Possible more specific
used to illuminate the no DTC first. GO
wrench light. crank, to Pinpoint
only Test D .
PARK,
REVERSE,
NEUTRAL
and 5th
gear
available,
harsh
engagements.

• Extremely
delayed
engagements
(until a
DTC is
set).
• After a
DTC is
set and
the
high
side
opened
- harsh
engagements,
poor
performance
(due to
a 5th
gear
drive
away),
no
shifts.
• Will
turn on
wrench
lamp.
P1705 - TR sensor TR circuit not TR sensor not - Rerun KOEO
indicating indicating Park or or KOER
park/neutral during Neutral during Key only.
self-test. ON Engine OFF
(KOEO) or Key ON
Engine Running
(KOER) self-test.
P1711 - TFT TFT sensor out of TFT sensor out of - RERUN
self-test range. self-test range equals KOEO or
less than -1°C (30°F) KOER only.
or greater than 105°C
(220°F) during KOEO
or KOER> self-test.
P1744 P0741 TCC TCC solenoid Sister code to P0741 Will turn on REFER to
circuit. used to illuminate the wrench lamp. Diagnosis By
wrench light. Symptom in
Additional common this section.
DTC, P163F.
P1780 - Transmission TCS (Overdrive TCS did not change Customer REFER to
Control Switch (O/D) Cancel) states during KOER cannot enter or Section
(TCS) circuit out of self-test. exit the 307-05A .
self-test range. overdrive
feature.
P1783 - Transmission Transmission over Transmission over REFER to
overtemperature temperature temperature condition Diagnosis By

condition. (greater than 135°C • Torque Symptom in

[275°F] for at least 5 converterthis section.
seconds). lockup
happens
earlier
than
expected.
• Will
turn on
wrench
lamp.
P1910 - Reverse lamp Reverse lamp Reverse lamp control REFER to
control control circuit/open. circuit fault. 6F35 • Reverse Section
TRan> sensor does lamps 417-01 .
not have a high do not
current reverse lamp function
control switch. This correctly.
has moved to the • Will
PCM. turn on
wrench
lamp.
P1921 P0706, P0707 TR switch Transmission range The PCM sets this REPAIR the
and P0708 signal DTC when the • Engine more specific
ignition switch is may DTC first. GO
turned to the crank not to Pinpoint
position and before crank. Test D .
the PCM receives an
engine run signal.
P2700 P0751 and Forward clutch Transmission This code sets with REPAIR the
P0752 system fault forward clutch either DTC P0751 or • Will more specific
apply time P0752. turn on DTC first.
range/performance. wrench REFER to
lamp. Diagnosis By
Symptom in
this section.
P2701 P0756 and Direct clutch Transmission direct This code sets with REPAIR the
P0757 system fault clutch apply time either DTC P0756 or • Will more specific
range/performance. P0757. turn on DTC first.
wrench REFER to
lamp. Diagnosis By
Symptom in
this section.
P2702 P0761 and Intermediate Transmission This code sets with REPAIR the
P0762 clutch system intermediate clutch either DTC P0761 or • Will more specific
faults apply time P0762. turn on DTC first.
range/performance. wrench REFER to
lamp. Diagnosis By
Symptom in
this section.
P2703 P0766 and Low/Reverse Transmission Low/reverse clutch REPAIR the
P2704 clutch and OWC low/reverse clutch stuck off with • Low/reverse
more specific
faults (covers apply time overdrive clutch stuck clutch DTC first.
just the clutches) range/performance. off. Most likely cause off is a REFER to

is SSD non-electrical ratio Diagnosis By

failure or based Symptom in
low/reverse/overdrive test. this section.
regulator valve stuck • Low/reverse
in default position. clutch
is only
tested
for
failed
off in
the low
manual
lever
position.
• The
customer
might
notice
no
engine
braking
in 1st
gear,
and
erratic
shifting
as the
diagnostics
isolates
the
fault to
low/reverse
clutch
failed
off.
• Delayed
or no
reverse
engagement.
• Will
turn on
wrench
lamp.
P2704 P0766, P0767 Overdrive clutch Transmission Overdrive clutch stuck REPAIR the
and P2703 system faults overdrive clutch off with low/reverse • Overdrivemore specific
apply time clutch stuck off. Most clutch DTC first.
range/performance. likely cause is SSD failed REFER to
non-electrical failure off. Diagnosis By
or • Will Symptom in
low/reverse/overdrive turn on this section.
regulator valve stuck wrench
in default position. lamp.
Overdrive clutch stuck

on. Possibly overdrive

clutch, SSD ,
low/reverse/overdrive
regulator valve stuck
in spring compressed
position.
P2705 - OWC failed Transmission OWC REFER to
apply time • The OWC • CustomerDiagnosis By
range/performance. holds in 1st might Symptom in
gear. If the notice this section.
OWC fails neutral
off, 1st gear is conditions
failed to when
neutral. 1st gear
• 1st gear is is
disabled for commanded.
this failure • Erratic
since shifting
low/reverse as the
clutch is not diagnostic
intended to isolates
hold power on the
torque in 1st cause
gear. of the
neutral
condition
to the
OWC
being
failed.
• Poor
launch
performance
(due to
2nd
gear
drive
away).
• Harsh
engagements.
• Will
turn on
wrench
lamp.
P2760 P0743 and TCC solenoid TCC pressure Intermittent TCC REPAIR the
P0744 control solenoid solenoid short to • Poor more specific
intermittent. ground. A short to launch DTC first. GO
ground will cause the performance
to Pinpoint
TCC to apply, which (due to Test A .
can stall the engine at 5th
low vehicle speeds. gear
The PCM will disable drive
the high side driver away).
until vehicle speed is

high enough that the • No

engine won't stall. TCC
apply.
With the high side • No
driver off the fault can shifts.
not be detected. If the • Will
fault goes away while turn on
the high side is off the wrench
vehicle will have a 5th lamp.
gear launch with no
DTC.
If this occurs 3 times

with no DTC P0742
being set, then DTC
P2760 will set.
P2783 - Torque Torque converter REFER to
converter temperature too • TCC control • Torque Diagnosis By
high. valve stuck in converterSymptom in
the apply this section.
temperature
position. too
When the high.
TCC is • Erratic
commanded shifts,
open there vehicle
will be no disengages
flow through at a
the TCC (both stop
apply and while
release in drive
circuits will or low,
be exhausted). early
• Test will run TCC
in 3rd gear or apply.
higher when • Will
valve 2 is in turn on
the latched MIL .
position,
pointing SSD
at overdrive
clutch when
the TCC is
commanded
open. SSE is
turned on, if
the control
valve is stuck,
this will cause
the TCC to
apply even
though the
TCC solenoid
is off.


Transaxle Connector Layouts
PCM Transaxle Harness - C175T
Pin Number Circuit Function

1 Transmission Range (TR), Output Shaft Speed (OSS) and Turbine Shaft Speed (TSS) voltage
supply
10 Shift Solenoid D (SSD) control
11 Shift Solenoid E (SSE) control
16 TSS sensor signal
19 Transmission Fluid Temperature (TFT) sensor signal
25 OSS sensor signal
31 Transmission Control Switch (TCS)
34 Line Pressure Control (LPC) control
36 TR , OSS and TSS sensor ground
39 TR signal
41 TFT ground
43 Shift Solenoid B (SSB) control
44 Shift Solenoid C (SSC) control
45 Shift Solenoid A (SSA) control
46 Torque Converter Clutch (TCC) solenoid control
50 Transaxle solenoid power control voltage
Transaxle Vehicle Harness - C1520A
Transaxle Connector Layouts 3705


1 Transmission Fluid Temperature (TFT) ground
2 TFT sensor signal
5 Transaxle solenoid power control voltage
7 ON/OFF Shift Solenoid E (SSE) control
17 Transmission Range (TR) signal
18 TR and Output Shaft Speed (OSS) sensor power
19 OSS sensor signal
20 TR / OSS sensor ground
Solenoid Body Leadframe-to-Transmission Range (TR) Sensor Internal Circuit Diagram
Transaxle Vehicle Harness - C1520A 3706

Solenoid Body Leadframe Main Connector Pin

Number TR Sensor Pin Number Circuit Function
18 1 Transmission Range
(TR) power
17 2 TR signal
20 3 TR ground
Transmission Range (TR) Sensor

1 Transmission Range (TR) power
2 TR signal
3 TR ground
Solenoid Body Leadframe Transmission Fluid Temperature (TFT) Sensor Pins

1 Transmission Fluid Temperature (TFT) signal return
2 TFT signal
Solenoid Body Leadframe-to-Output Shaft Speed (OSS) Sensor Internal Circuit Diagram
Solenoid Body Leadframe-to-Transmission Range (TR) Sensor Internal Circuit Diagram 3707
Solenoid Body Leadframe Main Output Shaft Speed (OSS)

Connector Pin Number Sensor Pin Number Circuit Function
20 1 Transmission Range (TR)/ Output Shaft
Speed (OSS) sensor ground circuit
19 3 OSS sensor signal
18 4 TR / OSS sensor power supply

1 Output Shaft Speed (OSS) sensor ground
3 OSS signal
4 OSS sensor power
Turbine Shaft Speed (TSS) Sensor - C1520B
Solenoid Body Leadframe-to-Output Shaft Speed (OSS) Sensor Internal Circuit Diagram 3708
Pin Number Ciuit Function

1 Turbine Shaft Speed (TSS) sensor ground
2 TSS sensor signal
3 TSS sensor power

1 Turbine Shaft Speed (TSS) sensor ground
2 TSS sensor signal
3 TSS sensor power
Solenoid Body Leadframe-to-Solenoid Internal Circuit Diagram
Solenoid Body Leadframe Main Connector Pin Number Circuit Function

Turbine Shaft Speed (TSS) Sensor - C1520B 3709

5 Solenoid power supply circuit

7 Shift Solenoid E (SSE) control
Solenoid Body Leadframe-to-Solenoid Internal Circuit Diagram 3710

Pinpoint Tests - OSC Equipped Vehicle
Special Tool(s)
Fluke 77-IV Digital Multimeter

FLU77-4 or equivalent

When an electrical conr solenoid body is disconnected, inspect the connector for terminal condition, corrosion
and contamination. Also inspect the connector seal for damage. Clean, repair or install new components as
required.
Shift Solenoid Pre-Diagnosis
Use the following shift solenoid operation information when carrying out Pinpoint Test A.
Solenoid Operation Chart
Shift Solenoid
Base Selector PCM SSA (VFS) SSC (VFS) SSD (VFS) SSE TCC
Lever Commanded NL (CB SSB (VFS) NL (CB NH (CB (On/Off) (VFS)
Position Gear 1,2,3,4) NH (3,5,R) 2,6) L,R/C 4,5,6) NC NL
D 1 On On Off Off a On b Off
2 On On On On Off Off
3 On Off Off On Off Off
4 On On Off Off Off On/Off
5 Off Off Off Off Off On/Off
6 Off On On Off Off On/Off
a Turns on above 8 km/h (5 mph).
b Turns off above 8 km/h (5 mph).
CB = Clutch brake
Pinpoint Tests - OSC Equipped Vehicle 3711

NH = Normally high
NL = Normally low
Shift Solenoid Failure Mode Chart "Failed ON" or "Failed OFF"
Failed ON/OFF due to PCM and/or vehicle wiring concerns and/or solenoid electrically, mechanically or
hydraulically stuck on/off.
Shift Solenoid A (SSA)
Actual Gears Obtained

Gear Commanded Failed ON (High Pressure) Failed OFF (Low Pressure)
R R R
D 1, 2, 3, 4 5, 6
Shift Solenoid B (SSB)

Gear Commanded Failed ON (Low Pressure) Failed OFF (High Pressure)
R Na R
D 1, 2, 4, 6 3, 5
a Reverse is available if the solenoid circuit failed causing transaxle solenoid power control solenoid to
remove voltage to all solenoids.
Shift Solenoid C (SSC)

R R R
D 2, 6 1, 3, 4, 5
Shift Solenoid D (SSD)

Gear Commanded Failed ON (Low Pressure) Failed OFF (High Pressure)
R Na R
Pinpoint Tests - OSC Equipped Vehicle 3712

D 1, 2, 3 b 4, 5, 6
a Reverse is available if the solenoid circuit failed causing transaxle solenoid power control solenoid to
remove voltage to all solenoids.

b No engine braking.
Shift Solenoid E (SSE)

R R R
D 1, 2 1, 2, 3, 4, 5, 6 a
a No engine braking.
Pinpoint Tests
Refer to Wiring Diagrams Cell 30 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ) for schematic and connector
information.
PINPOINT TEST A: TRANSAXLE CONTROL SOLENOIDS
NOTE: Refer to the transaxle connector illustrations and solenoid body leadframe internal wiring diagram
Transaxle Connector Layouts in this section.
Test Step Result / Action to Take

A1 ELECTRONIC DIAGNOSTICS
Yes
• Check to make sure the transaxle harness GO to A2 .
connector is fully seated, terminals are
engaged in connector and in good No
condition before proceeding. PRESS START. If vehicle does not enter Output
• Connect the scan tool. Test Mode, REFER to the Powertrain
• Carry out the Key ON Engine OFF Control/Emissions Diagnosis (PC/ED) manual.
(KOEO) until continuous DTCs have been
displayed.
• Enter the Output Test Mode.
• Select the mode ALL ON. Push START to
turn outputs ON. Push STOP to turn
outputs OFF.
• Does vehicle enter Output Test Mode?
A2 CHECK THE SOLENOID CIRCUIT FOR
AN OPEN
PINPOINT TEST A: TRANSAXLE CONTROL SOLENOIDS 3713

• Ignition OFF. Yes

• Disconnect: Transaxle Vehicle Harness GO to A3 .
C1520A.
• Use a mirror to inspect both ends of the No
connector for damage or pushed-out pins, REPAIR the circuit(s) for an open. RECONNECT
corrosion, loose wires and missing or all components. TEST the system for normal
damaged seals. operation.
• Disconnect: PCM Transaxle Harness
C175T .
• Use a mirror to inspect both ends of the
connector for damage or pushed out pins,
corrosion, loose wires and missing or
damaged seals.
• Measure the resistance of the suspect
solenoid circuit between the PCM
transaxle harness C175T and transaxle
vehicle harness C1520A using the
following chart.
Transaxle
Vehicle
Shift Solenoid Harness PCM
Shift Solenoid C1520A-8C175T-45
A (SSA)
CET05
(BU/GN)
Shift Solenoid C1520A-9 C175T-43
B (SSB)
CET06
(GN/BN)
C (SSC)
CET07
(GY/OG)
D (SSD)
CET08
(BN/WH)
E (SSE) CET18
(GY/YE)
Line Pressure C1520A-3 C175T-34
Control (LPC)
CET09
(YE/VT)
Torque C1520A-6 C175T-46
Converter
Clutch (TCC)
CET10

(BU/GY)
• Is the resistance less than 5 ohms?

A SHORT TO GROUND
Yes
• Measure the resistance between the GO to A4 .
transaxle vehicle harness C1520A, harness
side and ground using the following chart. No
REPAIR the circuit(s) for a short to ground.
RECONNECT all components. TEST the system for
normal operation.
Transaxle
Vehicle
Shift Solenoid Harness Ground
Shift Solenoid A C1520A-8 Ground
(SSA) CET05
(BU/GN)
Shift Solenoid B C1520A-9 Ground
(SSB) CET06
(GN/BN)
Shift Solenoid C C1520A-4 Ground
(SSC) CET07
(GY/OG)
Shift Solenoid D C1520A-10 Ground
(SSD) CET08
(BN/WH)
Shift Solenoid E C1520A-7 Ground
(SSE) CET18
(GY/YE)
Line Pressure C1520A-3 Ground
Control (LPC)
CET09 (YE/VT)
Torque C1520A-6 Ground
Converter Clutch
(TCC) CET10
(BU/GY)
• Is the resistance greater than 10,000

ohms?
A SHORT TO POWER
Yes
• Measure the voltage between the transaxle REPAIR the circuit(s) for a short to power.
vehicle harness electrical C1520A, harness RECONNECT all components. TEST the system for
side and ground using the following chart. normal operation.
No
GO to A5 .

Transaxle
Vehicle
Shift Solenoid Harness Ground
Shift Solenoid A C1520A-8 Ground
(SSA) CET05
(BU/GN)
Shift Solenoid B C1520A-9 Ground
(SSB) CET06
(GN/BN)
Shift Solenoid C C1520A-4 Ground
(SSC) CET07
(GY/OG)
Shift Solenoid D C1520A-10 Ground
(SSD) CET08
(BN/WH)
Shift Solenoid E C1520A-7 Ground
(SSE) CET18
(GY/YE)
Line Pressure C1520A-3 Ground
Control (LPC)
CET09 (YE/VT)
Torque C1520A-6 Ground
Converter Clutch
(TCC) CET10
(BU/GY)
• Is any voltage present?

A5 CHECK THE RESISTANCE OF THE
SOLENOID FIELD CIRCUIT
Yes
• Measure the resistance between the INSTALL a new PCM. REFER to Section 303-14A
transaxle solenoid body leadframe main or Section 303-14B . RECONNECT all components.
electrical connector C1520A-5, component TEST the system for normal operation.
side and the suspect solenoid pin,
component side and compare the value to
No
the specifications in the table below.
REMOVE the main control cover. REFER to Main
Control Cover in this section. INSPECT the solenoid
body for foreign material such as metal shavings on
the exposed metal contacts or other components.
CLEAR the solenoid body and RECHECK the
Solenoid C1520A-5 resistance values. If the resistance values are still out
Shift Body Lead - (Component of specification, GO to A6 . INSTALL a new
Solenoid Frame Pin Side) solenoid(s). REFER to Solenoids in this section.
Shift C1520A-8 C1520A-5 RECONNECT all components. TEST the system for
Solenoid A normal operation.
(SSA)
Shift C1520A-9 C1520A-5
Solenoid B
(SSB)
Shift C1520A-4 C1520A-5
Solenoid C

(SSC)
Shift C1520A-10 C1520A-5
Solenoid D
(SSD)
Shift C1520A-7 C1520A-5
Solenoid E
(SSE)
Line C1520A-3 C1520A-5
Pressure
Control
(LPC)
Torque C1520A-6 C1520A-5
Converter
Clutch
(TCC)
Solenoid Resistance Values: SHIFT

SOLENOID A (SSA), SHIFT
SOLENOID B (SSB), SHIFT
SOLENOID C (SSC), SHIFT
SOLENOID D (SSD), TORQUE
CONVERTER CLUTCH (TCC) and
LINE PRESSURE CONTROL (LPC)
Temperature
°C °F Resistance (ohms)
-20 to -10 -4 to 14 3.24-5.13
-10 to 0 14-32 3.43-5.32
0-10 32-50 3.62-5.51
10-20 50-68 3.81-5.70
20-30 68-86 4.00-5.89
30-40 86-104 4.19-6.08
40-50 104-122 4.38-6.27
50-60 122-140 4.57-6.46
60-70 140-158 4.76-6.65
70-80 158-176 4.95-6.83
80-90 176-194 5.13-7.02
90-100 194-212 5.32-7.21
Solenoid Resistance Values: SHIFT

SOLENOID E (SSE) (ON/OFF)
Temperature
Resistance (ohms)

°C °F
-20 to -10 -4 to 14 15.45-24.35
-10 to 0 14-32 16.35-25.25
0-10 32-50 17.25-26.15
10-20 50-68 18.15-27.05
20-30 68-86 19.05-27.95
30-40 86-104 19.95-28.85
40-50 104-122 20.85-29.75
50-60 122-140 21.75-30.65
60-70 140-158 22.65-31.54
70-80 158-176 23.54-32.44
80-90 176-194 24.44-33.34
90-100 194-212 25.34-34.24
• Is the resistance within specifications?

A6 CHECK THE SOLENOID BODY
LEADFRAME FOR AN OPEN
Yes
• Remove the solenoid body leadframe. INSTALL a new solenoid(s). REFER to Solenoids in
Refer to Solenoid Body Leadframe in this this section. RECONNECT all components. TEST
section. the system for normal operation.
• Measure the resistance between the
solenoid body leadframe main electrical No
connector C1520A, component side and INSTALL a new solenoid body leadframe. REFER
the corresponding solenoid pins using the to Solenoid Body Leadframe in this section.
following chart.
Solenoid Body
Leadframe Main
Connector Pin
Number Circuit Function
3 Line Pressure
Control (LPC)
solenoid control
4 Shift Solenoid C
(SSC) control
5 Solenoid power
supply
6 Torque Converter
Clutch (TCC)
solenoid control
7 Shift Solenoid E
(SSE) control
8 Shift Solenoid A
(SSA) control
9

Shift Solenoid B
(SSB) control
10 Shift Solenoid D
(SSD) control
PINPOINT TEST B: TFT SENSOR
Result / Action to
Test Step
Take
B1 ELECTRONIC DIAGNOSTICS
Yes
• Check to make sure the transaxle vehicle harness C1520A is fully seated, GO to B2 .
terminals are fully engaged in connector and in good condition before
proceeding. No
• Have the above items been checked? CARRY OUT
checks. CLEAR the
DTCs. REPEAT the
self-test.
B2 CHECK THE TFT SENSOR CIRCUITS FOR AN OPEN
Yes
• Ignition OFF. GO to B3 .
• Disconnect: Transaxle Vehicle Harness C1520A.
• Disconnect: PCM Transaxle Harness C175T. No
• Use a mirror to inspect both ends of the connector for damage or REPAIR the
pushed-out terminals, corrosion, loose wires and missing or damaged circuit(s) for an open.
seals. CONNECT all
• Measure the resistance between PCM transaxle harness C175T-19, circuit components. TEST
VET27 (BN/YE) and transaxle vehicle harness C1520A-2, circuit VET27 the system for
(BN/YE). normal operation.
PINPOINT TEST B: TFT SENSOR 3719

• Measure the resistance between PCM transaxle harness C175T-41, circuit

RE406 (GY/VT) and transaxle vehicle harness C1520A-1, circuit RE406
(GY/VT).

B3 CHECK THE TFT SENSOR CIRCUITS FOR A SHORT TO GROUND
Yes
• Disconnect: Catalyst Monitor Sensor (CMS) C141. GO to B4 .
• Disconnect: CMS C142.
• Measure the resistance between transaxle vehicle harness C1520A-2, No
circuit VET27 (BN/YE) and ground. REPAIR the
circuit(s) for a short
to ground.
CONNECT all
components. TEST
the system for
normal operation.
• Measure the resistance between transaxle vehicle harness C1520A-1,

circuit RE406 (GY/VT) and ground.
• Is the resistance greater than 10,000 ohms?

B4 CHECK THE TFT CIRCUITS FOR A SHORT TO VPWR

• Measure the voltage between transaxle vehicle harness C1520A-2, circuit Yes
VET27 (BN/YE) and ground. REPAIR the
circuit(s) for a short
to voltage.
CONNECT all
components. TEST
the system for
normal operation.
No
GO to B5 .
• Measure the voltage between transaxle vehicle harness C1520A-1, circuit
RE406 (GY/VT) and ground.

B5 CHECK THE RESISTANCE OF THE TFT SENSORS/HARNESS
Yes
• Vehicle must be at normal operating temperature. INSTALL a new
• Connect: Transaxle Vehicle Harness C1520A. PCM. CONNECT all
• TEST 1. components. TEST
• Measure and record the resistance between PCM transaxle harness the system for
C175T-19, circuit VET27 (BN/YE) and C175T-41, circuit RE406 normal operation.
(GY/VT).
No
INSTALL a new
solenoid body
leadframe. REFER to
Solenoid Body
Leadframe in this
section.
RECONNECT all
components. TEST
the system for
• Compare the resistance value to the following table ranges:
normal operation.
TRANSMISSION FLUID TEMPERATURE (TFT)
°C °F Resistance (Ohms)
-40 to -20 -40 to -4 1076K-269K
-19 to -1 -3 to 31 309K-91K
0-20 32-68 104K-35K 21-40 69-104 40K-15K

41-70 105-158 17K-4.9K

71-90 159-194 5.6K-2.5K
91-110 195-230 3.0K-1.4K
111-130 231-266 1.7K-0.8K
131-150 267-302 0.97K-0.56K
• TEST 2.
• Check for intermittent short or open.
• If the resistance was between 0.8K and 100K ohms carry out the
following test. If the transaxle is warm, allow it to cool. Check the TFT
sensor resistance again. Compare the resistance with the initial resistance.
The resistance should decrease if the transaxle was heated and should
increase if the transaxle was allowed to cool. If correct, then change in the
resistance occurs, repeat On-Board Diagnostic (OBD).
• Is the resistance in range?
PINPOINT TEST C: OSS SENSOR
NOTE: Output Shaft Speed (OSS) codes may be a result of a bad common power or ground shared between
the Transmission Range (TR) sensor, OSS sensor and Turbine Shaft Speed (TSS) sensor.

C1 ELECTRONIC DIAGNOSTICS
Yes
• Check to make sure the transaxle vehicle harness GO to C2 .
C1520A is fully seated, terminals are engaged in
connector and in good condition before No
proceeding. CARRY OUT the checks. CLEAR the
• Have the items above been checked? codes. RERUN the On-Board Diagnostic
(OBD) tests.
C2 ELECTRONIC DIAGNOSTICS
Yes
• Connect the scan tool. The condition that set the DTC is
• Monitor the OSS sensor PIDs while test driving intermittent and is not currently present.
the vehicle. CLEAR the DTCs. RERUN the OBD tests.
• Is the OSS sensor signal present and consistent?
No
GO to C3 .
C3 CHECK THE VEHICLE HARNESS FOR AN
OPEN CIRCUIT
Yes
• Disconnect: Transaxle Vehicle Harness C1520A. GO to C4 .
• Disconnect: PCM Transaxle Harness C175T.
• Use a mirror to inspect both ends of the connectors No
for damage or pushed-out terminals, corrosion, REPAIR the circuit(s) for an open.
loose wires and missing or damaged seals. CONNECT all components. TEST the
• Measure the resistance for the OSS sensor circuit, system for normal operation.
PINPOINT TEST C: OSS SENSOR 3722

between the transaxle vehicle harness C1520A and

the PCM transaxle harness C175T, harness using
the following chart.
Transaxle
Output Shaft Speed Vehicle
Sensor Circuit Harness PCM
Output Shaft Speed C1520A-18 C175T-1
(OSS) sensor power
supply LE111
(VT/GN)
OSS sensor ground C1520A-20 C175T-36
RET24 (BN/BU)
OSS sensor signal C1520A-19 C175T-25
VET26 (BN/GN)

C4 CHECK THE VEHICLE HARNESS FOR A
SHORT TO GROUND
Yes
• Disconnect: Transaxle Vehicle Harness C1520B. GO to C5 .
• Measure the resistance for the OSS sensor circuit
between the transaxle vehicle harness C1520A and No
ground using the following chart. REPAIR the circuit(s) for a short to ground.
CONNECT all components. TEST the
system for normal operation.
Transaxle
Sensor Circuit Harness Ground
Transmission Range C1520A-18 Ground
(TR)/ OSS sensor power
supply LE111 (VT/GN)
TR / OSS sensor ground C1520A-20 Ground
RET24 (BN/BU)
OSS sensor signal C1520A-19 Ground
VET26 (BN/GN)

C5 CHECK THE VEHICLE HARNESS FOR A
SHORT TO VPWR
Yes
• Check for voltage between the OSS sensor circuits REPAIR the circuit(s) for a short to voltage.
and the transaxle vehicle harness C1520A using CONNECT all components. TEST the
the following chart. system for normal operation.
No

GO to C6 .
Transaxle
Sensor Circuit Harness Ground
Transmission Range C1520A-18 Ground
(TR)/ OSS sensor power
supply LE111 (VT/GN)
TR / OSS sensor ground C1520A-20 Ground
RET24 (BN/BU)
OSS sensor signal C1520A-19 Ground
VET26 (BN/GN)

C6 CHECK THE SOLENOID BODY FOR AN
INTERNAL OPEN CIRCUIT
Yes
• Remove the main control cover. Refer to Main GO to C7 .
Control Cover in this section.
• Disconnect: TR Sensor. No
• Disconnect: OSS Sensor. INSTALL a new solenoid body leadframe.
• Use a mirror to inspect both ends of the connectors REFER to Solenoid Body Leadframe in this
for damage or pushed-out terminals, corrosion, section. CONNECT all components. TEST
loose wires and missing or damaged seals. the system for normal operation.
• Measure the resistance of the solenoid body
internal sensor power circuit between the main
solenoid body leadframe connector pin 18,
leadframe side and the OSS sensor connector pin
4, leadframe side.

internal sensor signal circuit between the main
3, leadframe side.


internal sensor ground circuit between the main
1, leadframe side.

C7 CHECK FOR VOLTAGE AND GROUND AT
THE OSS SENSOR CONNECTOR
Yes
• Connect: PCM C175T. INSTALL a new speed sensor. REFER to
• Connect: Transaxle Vehicle Harness C1520A. Output Shaft Speed (OSS) Sensor in this
• Ignition ON. section. TEST the system for normal
• Measure the voltage on the solenoid body operation. If the condition is still present,
leadframe between OSS sensor connector pins 1 INSTALL a new PCM. REFER to Section
and 4. 303-14A or Section 303-14B .
No
INSTALL a new PCM. REFER to Section
303-14A or Section 303-14B . CONNECT
all components. TEST the system for normal
operation.

• Is the voltage greater than 10 volts?
PINPOINT TEST D: TR SENSOR
NOTE: Transmission Range (TR) codes may be a result of a bad common power and ground shared between
the TR sensor, Output Shaft Speed (OSS) sensor and Turbine Shaft Speed (TSS) sensor.

D1 VERIFY DTCs
Yes
• Ignition OFF. GO to D3 .
• Select PARK.
• Start the engine. No
• Carry out the On-Board Diagnostic (OBD) GO to D2 .
Test. DTCs P0706, P0707 and P0708 cannot
be set by an incorrectly adjusted selector lever
cable.
• Are only TR DTC codes present?
D2 VERIFY SELECTOR LEVER
CABLE/LINKAGE ADJUSTMENT
Yes
• Verify that the selector lever cable/linkage is GO to D3 .
correctly adjusted. Refer to Section 307-05A .
• Is the selector lever cable/linkage correctly No
adjusted? ADJUST the selector lever cable/linkage.
REFER to Section 307-05A . GO to D4 .
D3 CHECK THE ELECTRICAL SIGNAL
OPERATION
Yes
• Select PARK. REPAIR as required. CLEAR the DTCs and
• Disconnect: PCM Transaxle C175T. RERUN OBD tests.
• Disconnect: Transaxle Vehicle Harness
C1520A. No
• Use a mirror to inspect both ends of the GO to D4 .
connectors for damaged or pushed-out
terminals, corrosion, loose wires and missing
or damaged seals.
• Is there damage to the connectors, terminals
or harness?
D4 CHECK ELECTRICAL SYSTEM
OPERATION ( TR AND PCM)
PINPOINT TEST D: TR SENSOR 3726


• Connect the scan tool. The problem is not in the TR sensor system.
• Connect: PCM Transaxle Harness C175T. REFER to Diagnosis By Symptom in this
• Connect: Transaxle Vehicle Harness C1520A. section for further diagnosis.
• Ignition ON.
• Enter the following diagnostic mode on the No
scan tool: TR PIDs TR_DC and TR_FREQ. If the PIDs change when wiggling the harness or
• Move the selector lever into each gear and driving the vehicle, the problem may be
stop. intermittent. GO to D5 .
• Observe the following PIDs; TR_DC and
TR_FREQ while wiggling harness or driving
the vehicle.
• Monitor PID: TR_FREQ.
• Compare the PID: TR_DC to the TR position
Duty Cycle Chart.
Selector Lever Range (% Duty

Position Cycle)
P 8.0 - 25.8
R 37.50 - 49.31
N 54.54 - 62.49
D 67.35 - 81.15
L 81.15 - 92
• Is PID TR_FREQ between 100 to 150 Hz?
Is PID TR_DC in range?
Do the PIDs TR_DC and TR_FREQ remain

steady when the harness is wiggled or the
vehicle driven?
D5 CHECK THE TRANSAXLE VEHICLE
HARNESS FOR AN OPEN
Yes
• Disconnect: PCM Transaxle Harness C175T. GO to D6 .
• Disconnect: Transae Harness C1520A.
• Measure the resistance for the TR sensor No
circuits between the transaxle vehicle harness REPAIR the circuit. CONNECT all
C1520A and the PCM transaxle harness components. TEST the system for normal
C175T using the following chart. operation.
Transmission Transaxle
Range Sensor Vehicle
Circuit Harness PCM
TR Ground RET24 C1520A-20 C175T-36
(BN/BU)

TR Signal VET32 C1520A-17 C175T-39

(VT)
TR Power LE111 C1520A-18 C175T-1
(VT/GN)

HARNESS FOR A SHORT TO GROUND
Yes
• Disconnect: Transaxle Vehicle Harness GO to D7 .
C1520B.
• Measure the resistance for the TR sensor No
circuits between the transaxle vehicle harness REPAIR shorted circuit(s). RECONNECT all
C1520A and ground using the following chart. components. TEST the system for normal
operation.
Circuit Harness Ground
TR Ground RET24 C1520A-20 Ground
(BN/BU)
TR Signal VET32 C1520A-17 Ground
(VT)
TR Power LE111 C1520A-18 Ground
(VT/GN)
• Are all resistances greater than 10,000

ohms?
HARNESS FOR A SHORT TO POWER
Yes
• Measure the voltage for the TR sensor circuits REPAIR shorted circuit(s). RECONNECT all
between the transaxle vehicle harness C1520A components. TEST the system for normal
and ground using the following chart. operation.
No
GO to D8 .
Circuit Harness Ground
TR Ground RET24 C1520A-20 Ground
(BN/BU)
TR Signal VET32 C1520A-17 Ground
(VT)
TR Power LE111 C1520A-18 Ground
(VT/GN)

D8 CHECK FOR A SHORT BETWEEN TR

/PCM INPUT SIGNAL CIRCUITS
Yes
• Measure the resistance between TR sensor GO to D9 .
circuits at the transaxle vehicle harness
C1520A using the following chart. No
REPAIR shorts on circuits having less than
10,000 ohms between other TR /PCM input
signal circuits. RECONNECT all components.
TEST the system for normal operation.
Transaxle Transaxle
Vehicle TR Sensor Vehicle
Harness Circuit Harness
C1520A-20 TR Ground C1520A-17
RET24 and
(BN/BU) C1520A-18
C1520A-17 TR Signal C1520A-18
VET32 (VT) and
C1520A-20
C1520A-18 TR Power C1520A-17
LE111 and
(VT/GN) C1520A-20
• Are all resistances greater than 10,000

ohms?
D9 CHECK FOR AN INTERNAL SOLENOID
BODY OPEN FOR THE TR SENSOR CIRCUITS
Yes
• Remove the main control cover. Refer to Main GO to D10 .
• Disconnect: TR Sensor Connector. No
• Use a mirror to inspect both ends of the INSTALL a new solenoid body leadframe.
connector for damage or pushed-out terminals, REFER to Solenoid Body Leadframe in this
corrosion, loose wires and missing or damaged section. RECONNECT all components. TEST
seals. the system for normal operation.
• Measure the resistance of the TR sensor
circuits between the solenoid body leadframe
main connector, component side and the TR
sensor connector, leadframe side.
Solenoid Body
Leadframe TR Sensor Circuit
Main Connector Pin Function
Pin Number Number (Wire Color)
18 1 Transmission
Range (TR)
power (RD)
17 2 TR signal
(WH)

20 3 TR ground
(BK)

D10 CHECK FOR VOLTAGE AND GROUND
AT THE TR SENSOR CONNECTOR
Yes
• Connect: PCM C175T. INSTALL a new TR sensor. REFER to Digital
• Connect: Transaxle Vehicle Harness C1520A. Transmission Range (TR) Sensor in this section.
• Ignition ON. TEST the system for normal operation. If the
• Measure the voltage on the solenoid body condition is still present, INSTALL a new PCM.
leadframe between TR sensor connector pins 1 REFER to Section 303-14A or Section 303-14B
(RD) and 3 (BK) solenoid body leadframe .
side.
No
303-14A or Section 303-14B . CONNECT all
components. TEST the system for normal
operation.
PINPOINT TEST E: TRANSAXLE SOLENOID PRESSURE CONTROL CIRCUIT
NOTE: Refer to the Transaxle Vehicle Harness Connector illustration Transaxle Connector Layouts in this
section.

E1 CHECK FOR VOLTAGE AT THE TRANSAXLE VEHICLE
HARNESS CONNECTOR
PINPOINT TEST E: TRANSAXLE SOLENOID PRESSURE CONTROL CIRCUIT 3730

NOTICE: Do not use a solenoid control circuit that may be at Yes

fault. Failure to jump pin 5 to a known good solenoid control INSTALL a new Line
circuit can cause incorrect diagnostic results. For additional Pressure Control (LPC)
information, REFER to Diagnostic Trouble Code (DTC) solenoid. REFER to
Charts in this section for a fault listing. Solenoids in this section.
RECONNECT all
• Ignition OFF. components. TEST the
• Disconnect: Transaxle Vehicle Harness C1520A. system for normal
• Inspect the connector for damaged or pushed out terminals, operation.
corrosion, loose wires and missing or damaged seals.
• Using the chart, connect a fused jumper between one of the 7 No
solenoid control circuit pins on the transmission vehicle harness GO to E2 .
C1520A and C1520A-5.
Transmission Vehicle Solenoid Control Circuit

Harness C1520A
C1520A-8 Shift Solenoid A (SSA) CET05
(BU/GN)
C1520A-9 Shift Solenoid B (SSB) CET06
(GN/BN)
C1520A-4 Shift Solenoid C (SSC) CET07
(GY/OG)
C1520A-10 Shift Solenoid D (SSD) CET08
(BN/WH)
C1520A-7 Shift Solenoid E (SSE) CET18
(GY/YE)
C1520A-3 Line Pressure Control (LPC) solenoid
CET09 (YE/VT)
C1520A-6 Torque Converter Clutch (TCC)
solenoid CET10 (BU/GY)
• Ignition ON.
• Measure the voltage between the transaxle vehicle harness
C1520A-5 circuit CET25 (BU/GN) harness side to ground.
E2 CHECK THE TRANSAXLE SOLENOID PRESSURE
CONTROL CIRCUIT FOR AN OPEN
PINPOINT TEST E: TRANSAXLE SOLENOID PRESSURE CONTROL CIRCUIT 3731


• Disconnect: PCM Transaxle Harness C175T. GO to E3 .
• Measure the resistance between the PCM transaxle C175T-50,
circuit CET25 (BU/GN) and transaxle vehicle harness C1520A-5, No
circuit CET25 (BU/GN). REPAIR circuit CET25
(BU/GN) for an open.
RECONNECT all
components. TEST the
system for normal
operation.

E3 CHECK THE TRANSAXLE SOLENOID POWER CONTROL
CIRCUIT FOR A SHORT TO GROUND
Yes
• Measure the resistance between the transaxle vehicle harness INSTALL a new PCM.
C1520A-5, circuit CET25 (BU/GN) and ground. REFER to Section 303-14A
or Section 303-14B .
RECONNECT all
system for normal
operation.
No
REPAIR circuit CET25
(BU/GN) for a short to
ground. RECONNECT all
system for normal
operation.
PINPOINT TEST F: TSS SENSOR
NOTE: Turbine Shaft Speed (TSS) sensor codes may be a result of bad power and ground circuits shared
between the Transmission Range (TR) sensor, Output Shaft Speed (OSS) sensor and TSS sensor.

F1 ELECTRONIC DIAGNOSTICS
Yes
• Check to make sure the transaxle vehicle harness GO to F2 .
C1520A is fully seated, terminals are engaged in
connector and in good condition before proceeding. No
• Have the items above been checked? CARRY OUT the checks. CLEAR the
DTCs. RERUN the On-Board Diagnostic
(OBD) tests.
PINPOINT TEST F: TSS SENSOR 3732

F2 ELECTRONIC DIAGNOSTICS
Yes
• Connect the scan tool. The condition that set the DTC is
• Monitor the TSS sensor PIDs while test driving the intermittent and is not currently present.
vehicle. CLEAR the DTCs. RERUN the OBD tests.
• Is the TSS sensor signal present and consistent?
No
GO to F3 .
F3 CHECK THE TRANSAXLE VEHICLE HARNESS
FOR AN OPEN CIRCUIT
Yes
• Disconnect: TSS Sensor C1520B. GO to F4 .
• Disconnect: PCM Transaxle Harness C175T.
• Use a mirror to inspect both ends of the connectors No
for damage or pushed-out terminals, corrosion, REPAIR the circuit(s) for an open.
loose wires and missing or damaged seals. CONNECT all components. TEST the
• Measure the resistance between the TSS C1520B system for normal operation.
and the PCM transaxle C175T.
Turbine Shaft Turbine Shaft

Speed (TSS) Sensor Speed (TSS)
Circuit Sensor PCM
TSS sensor power C1520B-3 C175T-1
supply LE111
(VT/GN)
TSS sensor ground C1520B-1 C175T-36
RET24 (BN/BU)
TSS sensor signal C1520B-2 C175T-16
VET33 (WH/OG)

FOR A SHORT TO GROUND
Yes
• Disconnect: Transaxle Vehicle Harness Connector GO to F5 .
C1520A.
• Measure the resistance between TSS sensor C1520B No
and ground. REPAIR the circuit(s) for a short to
ground. CONNECT all components. TEST
the system for normal operation.
Turbine Shaft
Turbine Shaft Speed Speed (TSS)
(TSS) Sensor Circuit Sensor Ground
TSS sensor ground C1520B-1 Ground
RET24 (BN/BU)
C1520B-2 Ground

TSS sensor signal

VET33 (WH/OG)
TSS sensor power C1520B-3 Ground
supply LE111
(VT/GN)

FOR A SHORT TO POWER
Yes
• Check for voltage between the TSS sensor C1520B REPAIR the circuit(s) for a short to
and ground. voltage. CONNECT all components. TEST
No
GO to F6 .
Turbine Shaft
Turbine Shaft Speed Speed (TSS)
(TSS) Sensor Circuit Sensor Ground
TSS sensor ground C1520B-1 Ground
RET24 (BN/BU)
TSS sensor signal C1520B-2 Ground
VET33 (WH/OG)
TSS sensor power C1520B-3 Ground
supply LE111
(VT/GN)

F6 CHECK FOR VOLTAGE AND GROUND AT THE
TSS SENSOR CONNECTOR
Yes
• Connect: PCM C175T. INSTALL a new speed sensor. REFER to
• Ignition ON. Turbine Shaft Speed (TSS) in this section.
• Measure the voltage between TSS sensor C1520B-1 TEST the system for normal operation. If
and C1520B-3. the condition is still present, INSTALL a
new PCM. REFER to Section 303-14A or
Section 303-14B .
No
303-14A or Section 303-14B . CONNECT
all components. TEST the system for
normal operation.


Special Testing Procedures
Special Tool(s)
Transmission Fluid Pressure Gauge

307-004 (T57L-77820-A)

The special tests are designed to aid the technician in diagnosing the hydraulic and mechanical portions of the
transaxle.
Engine Idle Speed Check
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the engine
idle speed.
Line Pressure Test
NOTICE: Carry out the Line Pressure Test prior to carrying out the Stall Speed Test. If the line
pressure is low at stall, do not carry out the Stall Speed Test or further transaxle damage will occur. Do
not maintain Wide Open Throttle (WOT) in any range for more than 5 seconds.
This test verifies that the line pressure is within specification.
1. Connect the Transmission Fluid Pressure Gauge to the line pressure tap.
2. Start the engine and check the line pressures. Refer to the Line Pressure Chart to determine if the line
pressure is within specification.
Special Testing Procedures 3736

Line Pressure Chart
Gear Line
Pressures at Idle a
P 338-379 kPa (49-55 psi)
R 621-689 kPa (90-100 psi)
N 338-379 kPa (49-55 psi)
D 338-379 kPa (49-55 psi)
L 338-379 kPa (49-55 psi)
Pressure at Wide Open
Throttle (WOT) Stall a
P N/A
R 1,868-2,068 kPa
(271-300 psi)
N N/A
D 1,868-2,068 kPa
(271-300 psi)
L 1,868-2,068 kPa
(271-300 psi)
a All pressures are approximate.
3. If the line pressure is not within specification, see the Line Pressure Diagnosis Chart for line pressure
concern causes.
4. When the pressure tests are complete, install the line pressure tap plug.
Line Pressure Diagnosis Chart
Test Results Possible Source

HIGH at IDLE - ALL RANGES Wiring Harnesses
Line Pressure Control (LPC) Solenoid
Main Regulator Valve

LOW at IDLE - ALL RANGES Low Transmission Fluid
Fluid Inlet Filter/Seal
Main Control Body
Cross Leaks

Gaskets
Pump
Separator Plate
LOW in Park ONLY Valve Body
LOW in Reverse ONLY Separator Plate
Reverse Clutch
Valve Body
Forward Clutch
LOW in Neutral ONLY Valve Body
LOW in Drive O/D ONLY Forward Clutch
Valve Body
LOW in Manual Low ONLY Forward Clutch
Valve Body
Stall Speed Test
WARNING: Block all wheels, set the parking brake and firmly apply the service brake to reduce the
risk of vehicle movement during this procedure. Failure to follow these instructions may result in
serious personal injury.
NOTICE: Carry out the Line Pressure Test prior to carrying out the Stall Speed Test. If the line
pressure is low at stall, do not carry out the Stall Speed Test or further transaxle damage will occur.
The Stall Speed Test checks:
• torque convertor operation and installation.

• holding ability of the forward clutch.
• reverse clutch.
• planetary One-Way Clutch (OWC).
• engine driveability concerns.
Conduct this test with the engine coolant and transmission fluid at correct levels and at normal operating
temperature.
Apply the park brake firmly for each Stall Speed Test.
Stall Speed Chart
Selector Lever Engine rpm

Drive 2.5 2,200-2,500

Drive 3.0 2,400-2,500
1. Connect the scan tool.
2. NOTE: If the recorded rpm exceeds the maximum limits, release the accelerator pedal immediately,
clutch slippage is indicated.
In each of the following ranges D, L and R, press the accelerator pedal to Wide Open Throttle
(WOT). Do not hold the throttle open for more than 5 seconds at a time.
3. Note the results in each range.
4. After each range, move the selector lever to NEUTRAL and run the engine at 1,000 rpm for about 15
seconds to cool the torque converter before going to the next test.
5. Use the stall speed diagnosis chart for corrective actions.
6. If stall speeds were too high, see the Stall Speed Diagnosis Chart. If stall speeds were too low, first
check engine idle speed and tune up. If engine is OK, remove torque converter and check TCC for
slippage.
Stall Speed Diagnosis Chart
Range Possible Source

D, L Forward Clutch
Low/Reverse Clutch
Low/One-Way Clutch
R Low/Reverse Clutch
Direct Clutch


Leakage Inspection
Special Tool(s)

Material
Item Specification
Dye-Lite® ATF/Power Steering Fluid -
Leak Detection Dye
164-R3701 (Rotunda)
XT-10-QLVC
NOTICE: Do not try to stop the fly increasing the torque beyond specifications. This may cause damage
to the case threads.
Leaks at the transaxle main control cover-to-transaxle often can be stopped by tightening the attaching bolts to
12 Nm (106 lb-in). If necessary, remove the main control cover and inspect for damage. Refer to Main
Check the transmission fluid filler tube connection at the transmission case. If leakage is found here, install a
new grommet.
Check transmission fluid tubes and fittings between the transmission and the cooler in the radiator tank for
wear or damage. When transmission fluid is found leaking between the case and the transmission fluid cooler
tube fitting, check for a missing or damaged O-ring, then tighten the fitting to specification.
If the leak continues, install a new transmission fluid cooler tube fitting and tighten to specification. The same
procedure should be followed for transmission fluid leaks between the radiator cooler and the transmission
fluid cooler tube fittings. Refer to Section 307-02A .
Check the engine coolant in the radiator. If transmission fluid is present in the coolant, the cooler in the
radiator is probably leaking. The cooler can be further checked for leaks by disconnecting the transmission
fluid cooler tubes from the cooler fittings and applying no more than 345 kPa (50 psi) air pressure to the
fittings. Remove the coolant recovery cap to relieve the pressure at the exterior of the transmission fluid
cooler tank. If the cooler is leaking and/or will not hold pressure, install a new cooler.
If transmission fluid leakage is found at the transaxle range selector lever, install a new seal.
If transmission fluid leakage is found at the transaxle internal harness connector, install a new O-ring.
Leakage Inspection 3741

Fluid Leakage in Torque Converter Area
Diagnosing and correcting fluid leaks in the torque converter area, use the following procedures to locate the
exact cause of the leakage. Leaks at the front of the transaxle, as evidenced by fluid around the torque
converter housing, may have several sources. By careful observation it is possible to pinpoint the source of the
leak before removing the transaxle from the vehicle. The paths which the fluid takes to reach the bottom of the
torque converter housing are shown in the illustration. The 5 steps following correspond with the numbers in
the illustration.
1. Transmission fluid leaking by the converter hub seal lip will tend to move along the drive hub and
onto the back of the torque converter. Except in the case of a total seal failure, transmission fluid
leakage by the lip of the seal will be deposited on the inside of the torque converter housing only, near
the outside diameter of the housing.
2. Transmission fluid leakage by the outside diameter of the converter impeller hub seal and the case
will follow the same path that leaks by the ID of the converter hub seal follow.
3. Transmission fluid leakage from the converter cover weld or the converter-to-flexplate stud weld will
appear at outside diameter of torque converter on the back face of the flexplate and in the converter
housing only near the flexplate. If a converter-to-flexplate lug, lug weld or converter cover weld leak
is suspected, remove the converter and pressure check.
4. Transmission fluid leakage from the bolts inside the converter housing will flow down the back of the
torque converter housing. Leakage may be from loose or missing bolts.
5. Engine oil leaks are sometimes incorrectly diagnosed as transaxle converter hub seal leaks. The
following areas of possible leakage should also be checked to determine if engine oil leakage is
causing the concern.
1. Leakage at the valve cover gasket may allow engine oil to flow over the torque converter
housing or seep down between the torque converter housing and cylinder block causing oil to
be present in or at the bottom of the torque converter housing.
2. Oil galley plug leaks will allow engine oil to flow down the rear face of the cylinder block to
the bottom of the torque converter housing.
3. Leakage at the crankshaft rear oil seal will work back to the flexplate, and then into the torque
converter housing.
4. Leakage at oil pressure sensor will allow engine oil to flow down the rear face of the cylinder
block to the bottom of the torque converter housing.
Leak Check Test
1. Remove the transmission fluid level indicator and note the color of the transmission fluid.
2. Remove the torque converter housing cover. Clean off any transmission fluid from the top and bottom
of the torque converter housing, the front of the case and rear face of the engine and oil pan. Clean the
torque converter area by washing with a suitable nonflammable solvent and blow-dry with
compressed air.

3. Wash the torque converter housing, the front of the flexplate and the converter drain plugs. The torque
converter housing may be washed out using cleaning solvent and a squirt-type oil can. Blow-dry all
washed areas with compressed air.
4. Using the scan tool, start and run the engine until the transaxle reaches its normal operating
temperature. Observe the back of the cylinder block and top of the torque converter housing for
evidence of transmission fluid leakage. Raise the vehicle on a hoist and run the engine at fast idle,
then at low idle, occasionally shifting to the OVERDRIVE and REVERSE ranges to increase pressure
within the transaxle. Observe the front of the flexplate, back of the cylinder block (in as far as
possible) and inside the torque converter housing and front of the case. Run the engine until
transmission fluid leakage is evident and the probable source of leakage can be determined.
Leak Check Test With Black Light
NOTE: Use Dye-Lite® ATF/Power Steering Fluid Leak Detection Dye to detect a transmission fluid leak.
1. Add dye to the transmission fluid. Use one 30 ml (1 oz) bottle of dye solution for every 3.8L (4 qt) of
transmission fluid.
2. Using the scan tool, start and run the engine until the transaxle reaches its normal operating
temperature. Using a suitable tool, observe the back of the cylinder block and top of the torque
converter housing for evidence of fluid leakage. Raise the vehicle on a hoist and run the engine at fast
idle, then at low idle, occasionally shifting to the DRIVE and REVERSE ranges to increase pressure
within the transaxle. Observe the front of the flexplate, back of the cylinder block (in as far as
possible), inside the torque converter housing and the entire case until fluid leakage is evident and
theprobable source of leakage can be determined.

Transmission Fluid Cooler
Special Tool(s)

Transaxle Cooling - 6F35
Part
1 8005 Radiator
2 7R081 Transmission fluid cooler supply tube assembly (supplies
transmission fluid to the transmission fluid cooler from
the transaxle)
3 7R081 Transmission fluid cooler return tube assembly
(transmission fluid return tube from the transmission fluid
cooler to the transaxle)
4 7J081 Secondary latches
5 7H420 Transaxle mounted transmission fluid cooler tubes
When internal wear or damage has occurred in the transaxle, metal particles or clutch plate material may have
been carried into the torque converter and transaxle fluid cooler. These contaminants are a major cause of
recurring transaxle issues and must be removed from the system before the transaxle is put back into use.
Transmission Fluid Cooler 3744

Refer to Transmission Fluid Cooler Backflushing and Cleaning in this section.
Transmission Fluid Cooler Flow Test
NOTE: The selector lever linkage, selector lever cable adjustment, transmission fluid level and line pressure
must be within specification before carrying out this test. Refer to Section 307-05A for selector lever linkage
and selector lever cable adjustment and refer to Special Testing Procedures in this section for line pressure
test. The transmission fluid must be above 85°C (185°F) for the cooler by-pass to open to carry out this test.
1. Using a scan tool, run the engine to establish the correct transmission fluid temperature of 85°C
(185°F).
2. Remove the transmission fluid level indicator from the transmission fluid filler tube.
3. Place funnel in the transmission fluid filler tube.
4. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02 .
5. Remove the transmission fluid cooler return tube (rear fitting) from the fitting on the transaxle case.
6. Connect one end of a hose to the cooler return tube and route other end of the hose up to a point
where it can be inserted into the funnel at the transmission fluid filler tube.
7. Start the engine and run it at idle with the transmission in NEUTRAL.
8. When transmission fluid flowing from hose is in a steady stream, a liberal amount of transmission
fluid should be observed. "Liberal" is described as about 1L (1 qt) delivered in 30 seconds. If a liberal
flow is observed, the test is cote.
9. If the flow is not liberal, stop the engine. Disconnect the hose from the cooler return tube and connect
it to the converter outlet tube fitting (front fitting) on the transaxle case.
10. Repeat Steps 7 and 8. If flow is now approximately 1L (1 qt) in 30 seconds, refer to Transmission
Fluid Cooler Backflushing and Cleaning . If the flow is still not approximately 1L (1 qt) in 30
seconds, repair the pump and/or the torque converter.
If new transmission fluid cooler tubes need to be installed, refer to Section 307-02A .
Transaxle Cooling - 6F35 3745


Transaxle/Transmission â 6F35 Workshop Manual
Diagnosis By Symptom
The Diagnostic Routines give the technician diagnostic information, direction and suggest possible
components, using a symptom as a starting point.
The Diagnostic Routines are divided into 2 categories: Electrical Routines, indicated by 200 series numbers,
and Hydraulic/Mechanical Routines, indicated by 300 series numbers. The Electrical Routines list the possible
electrical components that may cause or contribute to the symptom described. The Hydraulic/Mechanical
Routines list the possible hydraulic or mechanical components that may cause or contribute to the symptom
described.
Diagnosis by Symptom Index Directions
1. Using the Symptom Index, select the Concern/Symptom that best describes the condition.
2. See the routine indicated in the Diagnosis By Symptom Index.
3. Always begin diagnosis of a symptom with:

1. Preliminary inspections.
2. Verifications of condition.
3. Checking the fluid levels.
4. Carry out other test procedures as directed.
4. NOTE: Not all concerns and conditions with electrical components sets a DTC. Be aware that the
components listed may be the cause. Verify correct function of these components prior to proceeding
to the Hydraulic/Mechanical Routine.
Begin with the Electrical Routine, if indicated. Follow the Reference/Action statements. Always carry
out the OBD tests as required. Never skip steps. Repair as required. If the concern is still present after
electrical diagnosis, then proceed to the Hydraulic/Mechanical Routine.
5. The Hydraulic/Mechanical Routines list possible hydraulic or mechanical components that could
cause the concern. These components are listed in the removal sequence and by most probable cause.
All components listed must be inspected to verify a correct repair.
Diagnosis by Symptom Index
Routines
Title Electrical (1) Hydraulic/ Mechanical
Engagement Concerns
No Forward 201 301
No Reverse 202 302
Harsh Reverse 203 303
Harsh Forward 204 304
Delayed/Soft Reverse 205 305
Delayed/Soft Forward 206 306
Diagnosis By Symptom 3747

No Forward and No Reverse 207 307

Delayed/Soft Forward and Reverse 209 309
Shift Concerns
Some or All Shifts Missing 210 310
Timing â Early/Late 211 311
Timing â Erratic/Hunting 212 312
Soft/Slipping 213 313
Harsh 214 314
No 1st Gear, Engages in Higher Gear 215 315
No Manual Low â 1st Gear 216 316
No 1-2 Shift (Automatic) 220 320
Soft/Slipping 1-2 Shift (Automatic) 230 330
Harsh 1-2 Shift (Automatic) 240 340
Torque Converter Operation Concerns
Torque Converter: No Apply 250 350
Torque Converter: Always Applied/Stalls Vehicle 251 351
Torque Converter: Cycling/Shudder/Chatter 252 352

Other Concerns
No Engine Braking in 1st Gear, Manual 1st Position 260 360
Selector Lever Efforts High 261 361
External Leaks 262 362
Vehicle Driveability Concerns 263 363
Noise/Vibration â Forward or Reverse 264 364
Engine Will Not Crank 265 365
No Park Range 266 366
Overheating 267 367
(1) Carry out electrical routine first.
Diagnostic Routines
Engagement Concern: No Forward
Possible Component Reference/Action

201 â ELECTRICAL ROUTINE
Powertrain Control
System
• No electrical
concerns
301 â HYDRAULIC/MECHANICAL ROUTINE
Transmission Fluid
Level
• Low • CHECK transmission fluid level and adjust as necessary. REFER to

transmission Preliminary Inspection .
fluid level
• Condition • CARRY OUT transmission fluid condition check. REFER to Preliminary

Inspection .
Selector Lever Linkage
(Internal/External)
• Damaged or out • INSPECT for damage. REPAIR as required. VERIFY selector lever
of adjustment cable adjustment. REFER to Section 307-05A .
Incorrect Pressures
• LPC solenoid • CHECK pressure at line pressure tap. CARRY OUT Line Pressure Tests
stuck â low and Stall Speed Tests. REFER to Special Testing Procedures . SEE the
Line Pressure Chart for specification. If pressures are low, CHECK the
following possible components:
♦ Main control valve body

♦ Pump assembly
♦ LPC solenoid
Main Control Valve
Body

• Bolts out of • TIGHTEN bolts to specification.

torque
specification
• Gaskets and • INSTALL new as required.

separator plate
â damaged,
off location
• Manual control • INSTALL new as required.

valve â
damaged
Pump Assembly

torque
specification
• Porosity/cross • INSTALL a new pump as required.

leaks/ball
missing or
leaking
• Components • INSTALL a new pump as required.

â damaged
Engagement Concern: No Reverse

Powertrain Control
System
• No electrical
concerns
• Low transmission • CHECK transmission fluid level and adjust as necessary. REFER to
fluid level Preliminary Inspection .
• Transmission • CARRY OUT transmission fluid condition check. REFER to

fluid condition Preliminary Inspection .
(Internal/External)

• Damaged or out • REPAIR as required. VERIFY selector lever cable adjustment. REFER
of adjustment to Section 307-05A .
Incorrect Pressures
• Line pressure â • CARRY OUT Line Pressure and Stall Speed Tests. REFER to Special
low Testing Procedures . CHECK pressure at line pressure tap. SEE the Line
Pressure Chart for specifications. If pressures are low, CHECK the
following possible components:
♦ Main control valve body

♦ Pump assembly
♦ Low/reverse clutch assembly
♦ Direct clutch assembly
♦ SSB , SSD and SSE

torque
specification
• Gasket and • INSTALL new as required.

separator plate
â damaged, off
location
• Manual control • INSTALL new as required.

valve, springs
â stuck,
damaged
• Multiplex valve, • INSTALL new as required.

springs â
stuck, damaged
• Low/reverse • INSTALL new as required.

clutch valve,
springs â
stuck, damaged
• Direct clutch • INSTALL new as required.

valve, springs
â stuck,
damaged
Pump Assembly

torque
specification
• Porosity/cross • INSTALL a new pump as required.

leaks, pump

assembly leaking,
plugged hole
• Components • INSTALL a new pump as required.

damaged
Low/Reverse Clutch
Assembly
• SSD stuck â • INSTALL a new SSD as required. REFER to Solenoids .

low
• Low/reverse • REPAIR as required.

regulator valve
stuck
• Seals, piston, • REPAIR as required.

springs â
damaged
• Clearance check • CARRY OUT clearance checks.

out of
specification
• Friction elements • REPAIR as required.

â damaged or
worn
Direct Clutch Assembly
• Seals, piston, • REPAIR or install new as required.

spring â
damaged
• SSB • INSTALL a new SSB as required. REFER to Solenoids .
• Direct clutch • REPAIR or install new as required.

regulator valve
• Clearance check • CARRY OUT clearance checks.

out of
specification

â damaged,
clearance check
incorrect
Engagement Concern: Harsh Reverse


Powertrain Control System
• Electrical inputs/outputs, vehicle wiring • RUN OBD . REFER to the Powertrain

harnesses, TCM , MAF sensor, IAT sensor, Control/Emissions Diagnosis (PC/ED)
TP sensor, ISC , PSP sensor, engine rpm, LPC manual for diagnosis. GO to Pinpoint Test
solenoid, TFT sensor, TSS sensor, OSS A , GO to Pinpoint Test B , GO to Pinpoint
sensor, TR sensor, SSB , SSD or transmission Test C , GO to Pinpoint Test D and GO to
solenoid power control circuit open/shorted Pinpoint Test E .
Solenoid Body
• Incorrect solenoid body strategy data stored in • VERIFY solenoid body strategy data stored
the TCM in the TCM , download new identification
and strategy as necessary. REFER to
Solenoid Body Strategy .
Incorrect Pressures
• Line pressure â high • CARRY OUT Line Pressure and Stall

Speed Tests. REFER to Special Testing
Procedures . CHECK pressure at line
pressure tap. SEE the Line Pressure Chart
for specifications. If high, CHECK the main
control valve body.
Pump Assembly
• Bolts out of torque specification • TIGHTEN bolts to specification.
• Porosity/cross leaks, pump assembly leaking, • INSTALL a new pump as required.

plugged hole
• Components damaged • INSTALL a new pump as required.
• Main regulator valve â stuck, damaged • INSTALL new as required.

Main Controls
• Gasket and separator plate â damaged, off • INSTALL new as required.

location
• Low/reverse regulator valve â stuck, • INSTALL new as required.

damaged
• Low/Reverse latch valve â stuck, damaged • INSTALL new as required.
• Direct regulator valve â stuck, damaged • INSTALL new as required.

• Direct latch valve â stuck, damaged • INSTALL new as required.
• SSB mechanically stuck â high • INSTALL a new SSB as required. REFER

to Solenoids .
• SSD mechanically stuck â high • INSTALL a new SSD as required. REFER

to Solenoids .
Low/Reverse Clutch Assembly
• SSD stuck â low • INSTALL a new SSD as required. REFER

to Solenoids .
• Low/reverse regulator valve stuck • INSTALL a new solenoid body as required.
• Seals, piston, springs â damaged • REPAIR as required.
• Clearance check out of specification • CARRY OUT clearance checks.
• Friction elements â damaged or worn • REPAIR as required.

• Seals, piston, spring â damaged • REPAIR or INSTALL new as required.
• SSB stuck • INSTALL a new SSB as required. REFER

to Solenoids .
• Direct clutch regulator valve • REPAIR or INSTALL new as required.
• Clearance check out of specification • CARRY OUT clearance checks.
• Friction elements â damaged, clearance • REPAIR or INSTALL new as required.

check incorrect
Engagement Concern: Harsh Forward


harnesses, TCM , MAF sensor, IAT sensor, Control/Emissions Diagnosis (PC/ED) manual
TP sensor, ISC , PSP sensor, engine rpm, for diagnosis. GO to Pinpoint Test A , GO to
LPC solenoid, TFT sensor, TSS sensor, Pinpoint Test B , GO to Pinpoint Test C , GO
OSS sensor, TR sensor, SSA and or to Pinpoint Test D and GO to Pinpoint Test E
transmission solenoid power control circuit .
open/shorted
Solenoid Body

• Incorrect solenoid body strategy data stored • VERIFY solenoid body strategy data stored in
in the TCM the TCM , download new identification and
strategy as necessary. REFER to Solenoid
Body Strategy .
Incorrect Pressures
• Line pressure â high • CARRY OUT Line Pressure and Stall Speed
Tests. REFER to Special Testing Procedures .
Check pressure at line pressure tap. SEE the
Line Pressure Chart for specifications. If
pressures are high, CHECK the main control
valve body, pump assembly.
Pump Assembly
• Porosity/cross leaks, pump assembly • INSTALL a new pump as required.

leaking, plugged hole
• Components damaged • INSTALL a new pump as required.
• Main regulator valve â stuck, damaged • INSTALL new as required.

Main Controls
• Gasket and separator plate â damaged, • INSTALL new as required.

off location
• Forward clutch seal â leaking between • INSTALL new as required.

valve body and case
• Forward clutch regulator valve â stuck, • INSTALL new as required.

damaged
• Forward clutch latch valve â stuck, • INSTALL new as required.

damaged
Forward Clutch Assembly
• Seals, piston â worn, damaged • INSTALL new as required.
• Friction elements â damaged • INSTALL new as required.
• Wave spring â damaged • INSTALL new as required.
Engagement Concern: Delayed/Soft Reverse


• Electrical • RUN OBD . REFER to the Powertrain Control/Emissions Diagnosis

inputs/outputs, (PC/ED) manual for diagnosis. GO to Pinpoint Test A and GO to
vehicle wiring Pinpoint Test B .
harnesses, TCM ,
LPC solenoid, TFT
sensor
Solenoid Body
• Incorrect solenoid • VERIFY solenoid body strategy data stored in the TCM , download
body strategy data new identification and strategy as necessary. REFER to Solenoid
stored in the TCM Body Strategy .
• Transmission fluid • CARRY OUT transmission fluid condition check. REFER to

condition Preliminary Inspection .
(Internal/External)
• Damaged, out of • REPAIR as required. VERIFY selector lever cable adjustment.

adjustment REFER to Section 307-05A .
Incorrect Pressures
• Line pressure â • CHECK pressure at line pressure tap. CARRY OUT Line Pressure
low and Stall Speed Tests. REFER to Special Testing Procedures . SEE
the Line Pressure Chart for specifications. If pressures are low,
CHECK the following possible components: main control valve body,
pump assembly, low/reverse clutch assembly, direct clutch assembly.
Main Controls
• Bolts out of torque • TIGHTEN bolts to specification.

specification

separator plate â
damaged, off
location

regulator valve â
stuck, damaged
• INSTALL new as required.

• Low/reverse latch
valve â stuck,
damaged
• Direct regulator • INSTALL new as required.

valve â stuck,
damaged
• Direct latch valve • INSTALL new as required.

â stuck, damaged
• Manual control • REPAIR or INSTALL new as required.

valve, springs â
missing, damaged,
misassembled
• SSB stuck â low • INSPECT for damage. GO to Pinpoint Test A . INSTALL a new SSB
as required. REFER to Solenoids .
• SSD stuck â low • INSTALL a new SSD as required. REFER to Solenoids .

Pump Assembly
• Pump Assembly • INSTALL new as required.

â worn/cross
leaks, leaking
• Main regulator • INSTALL new as required.

valve â stuck,
damaged
Low/Reverse Clutch
Assembly
• SSD stuck â low • INSTALL a new SSD as required. REFER to Solenoids .

regulator valve
stuck
• Seals, piston, • REPAIR as required.

springs â
damaged
• Clearance check out • CARRY OUT clearance checks.

of specification

â damaged or
worn

• Seals, piston, spring • REPAIR or INSTALL new as required.

â damaged
• SSB stuck • INSTALL a new SSB as required. REFER to Solenoids .
• Direct clutch • REPAIR or INSTALL new as required.

regulator valve
• Clearance check out • CARRY OUT clearance checks.

of specification

â damaged,
clearance check
incorrect
Engagement Concern: Delayed/Soft Forward

• Electrical • RUN OBD . REFER to the Powertrain Control/Emissions

inputs/outputs, vehicle Diagnosis (PC/ED) manual for diagnosis. GO to Pinpoint Test A ,
wiring harnesses, TCM GO to Pinpoint Test B and GO to Pinpoint Test C .
, LPC solenoid, TFT
sensor and TSS sensor
Solenoid Body
• Incorrect solenoid body • VERIFY solenoid body strategy data stored in the TCM ,
strategy data stored in download new identification and strategy as necessary. REFER to
the TCM Solenoid Body Strategy .
• Low transmission fluid • CHECK transmission fluid level and adjust as necessary. REFER
level to Preliminary Inspection .


Incorrect Pressures
• Line pressure â low

• CHECK pressure at line pressure tap. CARRY OUT Line Pressure

and Stall Speed Tests. REFER to Special Testing Procedures .
SEE the Line Pressure Chart for specifications. If pressures are
low, CHECK the following possible components: main control
valve body, pump assembly, and forward clutch.
Main Controls

specification
• Gaskets and separator • INSTALL new as required.

plate â damaged, off
location
• Forward clutch • INSTALL new as required.

regulator valve stuck or
damaged
• Forward clutch latch • INSTALL new as required.

valve stuck or damaged
• LPC solenoid stuck • INSTALL a new LPC as required. REFER to Solenoids .

â low
• SSA stuck â low • INSTALL a new SSA as required. REFER to Solenoids .

Pump Assembly

specification
• Worn/cross leaks • INSTALL new as required.
• Main regulator valve • REPAIR as required.

â stuck, damaged,
missing
• Clutch plates, seals, • INSTALL new as required.

piston â worn,
damaged
• Wave spring â • INSTALL new as required.

damaged
Engagement Concern: No Forward and No Reverse

• No electrical
concerns
• Transmission • CARRY OUT transmission fluid condition check. REFER to

fluid condition Preliminary Inspection .
Halfshaft
• Splines â worn, • REPAIR as required.

damaged
• Shaft â • REPAIR as required.

misassembled,
incorrect
(Internal/External)
• Damaged, out of • REPAIR as required. VERIFY selector lever cable adjustment. REFER
adjustment to Section 307-05A .
Incorrect Pressures
• Line pressure â • CHECK pressure at the line pressure tap. CARRY OUT Line Pressure
low and Stall Tests. REFER to Special Testing Procedures . SEE the Line
Pressure Chart for specifications. If pressures are low, CHECK the
following possible components: transmission fluid filter and seal
assembly, main control, pump assembly, low/reverse clutch assembly,
forward clutch assembly.
Transmission Fluid Filter
and Seal Assembly
• Plugged, • INSTALL a new filter and seal assembly.

damaged, not
correctly seated
• Filter, seal â • INSTALL a new filter and seal assembly.

damaged
Main Controls
• Manual valve • INSTALL new as required.
• Shift valves • INSTALL new as required.

torque

specification

separator plate
â damaged, off
location
• Components â • REPAIR as required.

damaged, check
balls stuck
Pump Assembly

torque
specification
• Porosity/cross • INSTALL a new pump assembly.

leaks â leaking,
plugged hole
• Main regulator • REPAIR as required.

valve (only if line
pressure is out of
specification) â
damaged
Output Shaft
• Splines â • REPAIR as required.

damaged
Other Possible
Components
• Turbine shaft • REPAIR as required.
• Flexplate • REPAIR as required.
• Sun gear and shell • REPAIR as required.

assemblies
• Planetaries • REPAIR as required.
• Final drive • REPAIR as required.

assembly
Engagement Concern: Delayed/Soft Forward and Reverse


• Electrical inputs/outputs, • RUN OBD . REFER to Powertrain Control/Emissions Diagnosis

vehicle wiring harnesses, (PC/ED) manual for diagnosis. GO to Pinpoint Test A , GO to
TCM TFT sensor, TSS Pinpoint Test B and GO to Pinpoint Test C .
sensor, LPC solenoid
Solenoid Body
• Incorrect solenoid body • VERIFY solenoid body strategy data stored in the TCM ,
strategy data stored in the download new identification and strategy as necessary. REFER
TCM to Solenoid Body Strategy .
• Low transmission fluid • CHECK transmission fluid level and adjust as necessary.
level REFER to Preliminary Inspection .

(Internal/External)

Incorrect Pressures
• Line pressure â low • CARRY OUT Line Pressure and Stall Speed Tests. REFER to
Special Testing Procedures . SEE the Line Pressure Chart for
specifications. If pressures are low, CHECK the following
possible components: main control, pump assembly and LPC
solenoid.
Transmission Fluid Filter and
Seal Assembly
• Plugged, damaged, not • INSTALL a new filter and seal assembly.

correctly seated
• Filter, seal â damaged • INSTALL a new filter and seal assembly.

Main Controls

specification

location
• Seals, manual valve • REPAIR or INSTALL new as required.

Pump Assembly

specification
• Worn/cross leaks â • INSTALL a new pump assembly.

leaking
• Components damaged • INSTALL new as required.
• Main regulator valve â • REPAIR as required.

missing, damaged or
misassembled
Shift Concerns: Some or All Shifts Missing


harnesses, TCM , SSA , SSB , SSC , SSD , Control/Emissions Diagnosis (PC/ED) manual
SSE , TP sensor, MAF sensor, OSS for diagnosis. GO to Pinpoint Test A , GO to
sensor, TSS sensor, TR sensor and LPC Pinpoint Test C and GO to Pinpoint Test D .
solenoid
• Incorrect transmission fluid level • CHECK transmission fluid level and adjust as
necessary. REFER to Preliminary Inspection .
• Transmission fluid condition • CARRY OUT transmission fluid condition

check. REFER to Preliminary Inspection .
Selector Lever Linkage (Internal/External)
• Damaged, out of adjustment • REPAIR as required. VERIFY selector lever

cable adjustment. REFER to Section 307-05A .
Vehicle Speed Input
• Insufficient, erratic or no input received by • REPAIR as required. GO to Pinpoint Test C .

the TCM from the OSS sensor
Transmission Fluid Filter and Seal Assembly
• Plugged, damaged, not correctly seated • INSTALL a new filter and seal assembly.

Main Controls
• Regulator and/or latch valves â stuck, • REPAIR or install new as required.

damaged, misassembled
• Plugged solenoid body filter • INSTALL new as required.

Planetary Gear Sets
• Damaged • REPAIR as required.

Other Components
• Clutches • REPAIR as required.
• Output shafts (differential) • REPAIR as required.
• Powerflow components • REPAIR as required.
• Go to shift concerns: • See the appropriate shift concern and routine:
♦ Shift Concern: No 1-2, Routine 220/320

Shift Concerns: Timing â Early/Late

• Electrical inputs/outputs, vehicle wiring • RUN OBD . REFER to Powertrain

harnesses, TCM , SSA , SSB , SSC , SSD , Control/Emissions Diagnosis (PC/ED)
SSE , TP sensor, MAF sensor, OSS sensor, manual for diagnosis. GO to Pinpoint Test A
TSS sensor, IAT sensor, ECT sensor and , GO to Pinpoint Test B and GO to Pinpoint
LPC solenoid Test C .
• CARRY OUT Shift Point Road Test. REFER

to Shift Point Road Test . CARRY OUT
Torque Converter Operation Test. REFER to
Torque Converter Diagnosis .
Solenoid Body

• Incorrect solenoid body strategy data stored • VERIFY solenoid body strategy data stored
in the TCM in the TCM , download new identification
and strategy as necessary. REFER to
Solenoid Body Strategy .
Other
• Tire size • SEE the specification decal and verify

vehicle has original equipment. Changes in
tire size will affect shift timing.
• Low transmission fluid level • CHECK transmission fluid level and adjust
as necessary. REFER to Preliminary
Inspection .


cable adjustment. REFER to Section
307-05A .
Main Controls
• Gaskets and separator plate â damaged, • INSTALL new as required.

off location
• Valves, accumulators, seals, springs, clips, • REPAIR as required.

check balls â damaged, missing,
misassembled
One-Way Clutch Assembly
• Damaged • REPAIR or INSTALL new as required.

Other Components
• Clutches • REPAIR or INSTALL new as required.

Vehicle Speed Input
• Insufficient, erratic or no input received by • REPAIR as required. GO to Pinpoint Test C .

the TCM from the OSS or TSS sensors

Shift Concerns: Timing â Erratic/Hunting


harnesses, TCM , TCC solenoid, SSA , Control/Emissions Diagnosis (PC/ED) manual
SSB , SSC , SSD , SSE , TP sensor, OSS for diagnosis. GO to Pinpoint Test A , GO to
sensor, ECT sensor, IAT sensor, MAF Pinpoint Test B , GO to Pinpoint Test C , GO to
sensor, TR sensor, TFT sensor and TSS Pinpoint Test D and GO to Pinpoint Test E .
sensors
• CARRY OUT Shift Point Road Test. REFER to

Shift Point Road Test . CARRY OUT Torque
Converter Operation Test. REFER to Torque
Converter Diagnosis .
Solenoid Body
• Incorrect solenoid body strategy data • VERIFY solenoid body strategy data stored in
stored in the TCM the TCM , download new identification and
strategy as necessary. REFER to Solenoid Body
Strategy .
• Low transmission fluid level • CHECK transmission fluid level and adjust as


cable adjustment. REFER to Section 307-05A .
• Gaskets and separator plate â damaged, • INSTALL new as required.

off location
• Valves, seals, clips, check ball â stuck, • REPAIR or INSTALL new as required.
damaged, contaminated
Vehicle Speed Input

• Insufficient, erratic or no input received • REPAIR as required. GO to Pinpoint Test C .

by the TCM from the OSS sensor or TSS
sensor
TCC
• SEE Torque Converter Cycling (Routine

254/354).
Planetary Gear Sets
• Damaged • REPAIR as required.

Clutch Assemblies
• Damaged clutch plates, pistons, seals, • REPAIR or INSTALL new as required.

return springs

For Diagnosis Related to a Specific Shift
• SEE the appropriate shift concern and routine

for further diagnosis:

♦ Shift Concern: Soft/Slip 1-2, Routine 230/330
♦ Shift Concern: Harsh 1-2, Routine 240/340


Shift Concerns: Feel â Soft/Slipping

• Electrical inputs/outputs, vehicle • RUN OBD . REFER to Powertrain

wiring harnesses, TCM , LPC Control/Emissions Diagnosis (PC/ED) manual for
solenoid, MAF sensor, TP sensor, diagnosis. GO to Pinpoint Test A , GO to Pinpoint
ECT sensor, IAT sensor, TFT sensor, Test B and GO to Pinpoint Test C .
OSS sensor and TSS sensor
Solenoid Body
• Incorrect solenoid body strategy data

• VERIFY solenoid body strategy data stored in the
stored in the TCM TCM , download new identification and strategy as
necessary. REFER to Solenoid Body Strategy .
Transmission Fluid
• Low transmission fluid level • CHECK transmission fluid level and adjust as
• Transmission fluid condition • CARRY OUT transmission fluid condition check.

REFER to Preliminary Inspection .
• Damaged, out of adjustment • REPAIR as required. VERIFY selector lever cable

adjustment. REFER to Section 307-05A .
Incorrect Pressures
• Line pressure â low • CARRY OUT Line Pressure and Stall Speed Tests.
REFER to Special Testing Procedures . SEE the Line
Pressure Chart for specifications. If pressures are low
or all shifts are soft/slipping. REFER to Main
Control Valve Body .
• If pressures are OK and a specific shift is

soft/slipping, SEE the following chart:
♦ Soft/Slipping Shift 1-2, Routine 230/330



Transmission Fluid Filter and Seal
Assembly
• Plugged, damaged, not correctly • INSTALL a new filter and seal assembly.
seated

Main Controls
• Gaskets and separator plate â • INSTALL new as required.

damaged, off location
• Sticking or binding valves, check • REPAIR or INSTALL new as required.

balls, clips, springs â damaged,
missing
Pump Assembly
• Pump assembly â worn/cross • INSTALL new as required.

leaks, leaking
Shift Concerns: Feel â Harsh

• Electrical inputs/outputs, vehicle • RUN OBD . REFER to Powertrain Control/Emissions

wiring harnesses, TCM , LPC Diagnosis (PC/ED) manual for diagnosis. GO to Pinpoint
solenoid, MAF sensor, TP Test A , GO to Pinpoint Test B , GO to Pinpoint Test C
sensor, OSS sensor, TSS sensor, and GO to Pinpoint Test D .
ECT sensor, IAT sensor, PSP
switch, TFT sensor, TR sensor
SSA , SSB , SSC , SSD and SSE
Solenoid Body
• Incorrect solenoid body strategy

• VERIFY solenoid body strategy data stored in the TCM ,
data stored in the TCMdownload new identification and strategy as necessary.
REFER to Solenoid Body Strategy .

• Low transmission fluid level • CHECK transmission fluid level and adjust as necessary.
• Condition • CARRY OUT transmission fluid condition check.

Incorrect Pressures
• Line pressure â high • CARRY OUT Line Pressure and Stall Speed Tests.
REFER to Special Testing Procedures . CHECK pressure
at line pressure tap. SEE the Line Pressure Chart for
specifications. If pressures are high or all shifts are harsh,
CHECK the main control. REFER to Main Control Valve
Body . If pressures are OK and a specific shift is harsh.
SEE the appropriate shift routine in the following chart:
♦ Shift 1-2, Routine 240/340


• Valves, springs, clips, check • REPAIR or INSTALL new as required.

balls â stuck, damaged
Pump Assembly
• Pump assembly â worn/cross • INSTALL new as required.

leaks, leaking
Shift Concerns: No 1st Gear, Engages in Higher Gear


harnesses, TCM , SSA , SSB , SSC , Control/Emissions Diagnosis (PC/ED) manual for
SSD , SSE , OSS sensor, TSS sensor diagnosis. GO to Pinpoint Test A , GO to Pinpoint

and transmission solenoid power Test C and GO to Pinpoint Test E . REPAIR as

control circuit â no voltage at required. CLEAR the DTCs. ROAD TEST and
transmission connector RERUN OBD .

• Forward clutch regulator valve, springs, • REPAIR as required.

clips â stuck, damaged, missing,
misassembled
• Shift solenoid â stuck, damaged • REPAIR as required. GO to Pinpoint Test A .

ACTIVATE solenoid using output state control.
REPAIR as required.
• For diagnosis related to a specific gear, • SEE the following routines:

use the scan tool to select the gear
Mechanical
• Clutches or seals â damaged or worn • REPAIR or INSTALL new as required.

Low One-Way Clutch Assembly
• Not overrunning, damaged • INSTALL new as required.
Shift Concerns: No Manual Low â 1st Gear

• Electrical inputs/outputs, • RUN OBD . REFER to Powertrain Control/Emissions

vehicle wiring harnesses, Diagnosis (PC/ED) manual for diagnosis. GO to Pinpoint Test
TCM , SSA , SSD , SSE A and GO to Pinpoint Test D . REPAIR as required. CLEAR
and TR sensor the DTCs. ROAD TEST and RERUN OBD .
(Internal/External)

• Damaged or out of • REPAIR as required. VERIFY selector lever cable adjustment.

Incorrect Pressures
• Line pressure â low • CHECK pressure at line pressure tap. CARRY OUT Line
Pressure and Stall Speed Tests. REFER to Special Testing
Procedures . SEE the Line Pressure Chart for specifications. If
pressures are low, CHECK the following possible components:
main control. REFER to Main Control Valve Body .

specification

location
• Forward latch, forward • REPAIR as required.

regulator, low/reverse
latch, low/reverse
regulator valves, clips
â stuck, damaged,
missing
• Multiplex shift valve clips • CHECK 4th gear ratio. REPAIR as required.
â stuck, damaged,
missing
• Check ball â damaged, • REPAIR as required.

missing
• Seals, piston, spring â • REPAIR or INSTALL new as required.

damaged
• Clutches â damaged, • INSTALL new as required.

burnt, worn
• Worn, damaged, • REPAIR as required.

misassembled
• Seals, piston, spring â • REPAIR or INSTALL new as required.

damaged
• Clutches â damaged, • INSTALL new as required.

burnt, worn
• REPAIR as required.

• Worn, damaged,
misassembled
• Case â damaged • REPAIR as required.
Shift Concerns: No 1-2 Shift (Automatic)


TCM , SSC and TR A and GO to Pinpoint Test D .
sensor
Incorrect Pressures
• Line pressure • CHECK pressure at line pressure tap. CARRY OUT Line
Pressure Test. REFER to Special Testing Procedures . SEE the
Line Pressure Chart for specifications. If not OK, CHECK main
control. REFER to Main Control Valve Body .

specification

location
• Intermediate regulator • REPAIR or INSTALL new as required.

valve, springs, clips â
loose, stuck, missing,
misassembled stuck off
• SSC not functioning • ACTIVATE solenoid using scan tool. REFER to Output State
correctly Control (OSC) Mode . GO to Pinpoint Test A . INSTALL a
new solenoid as required. REFER to Solenoids .
Intermediate Clutch Assembly
â Failed Off
• Seals â damaged • INSTALL new as required.
• Piston â damaged • INSTALL new as required.

• Friction â damaged,
worn
• Cylinder hub â • INSTALL new as required.

damaged
• Return spring assembly • INSTALL new as required.

â damaged
â Failed On
• Friction â overheated • INSTALL new as required.
• Cylinder hub â • INSTALL new as required.

damaged

â damaged
Pump Assembly
• Component damaged • INSTALL a new pump assembly as required.

• Not overrunning, • INSTALL new as required.

damaged


TCM , SSB failed, SSC A and GO to Pinpoint Test D .
stuck on and TR sensor
Incorrect Pressures
• Line pressure • CARRY OUT Line Pressure Test. REFER to Special Testing
Procedures . CHECK pressure at line pressure tap. SEE the
Line Pressure Chart for specifications. If not OK, CHECK


specification
• gaskets and separator plate • INSTALL new as required.

â damaged, off location
• Direct regulator and latch • REPAIR or INSTALL new as required.

valves, springs, clips â
misassembled, stuck off
• Intermediate regulator and • REPAIR or INSTALL new as required.

latch valves, springs, clips
â loose, stuck, missing,
misassembled, stuck on
• SSB or SSC not functioning • ACTIVATE solenoid using scan tool. REFER to Output State
Direct Clutch Assembly â Failed
Off
• Friction â damaged, • INSTALL new as required.

worn
• Cylinder hub â damaged • INSTALL new as required.
• Return spring assembly â • INSTALL new as required.

damaged
Intermediate Clutch Assembly â
Failed On

worn

damaged



harnesses, TCM , SSD failed, SSB stuck Control/Emissions Diagnosis (PC/ED)
on and TR sensor manual for diagnosis. GO to Pinpoint Test
A and GO to Pinpoint Test D .

• Overdrive regulator and latch valves, • REPAIR or INSTALL new as required.

springs, clips â loose, stuck, missing,
misassembled, clutch failed off
• Direct regulator and latch valves, • REPAIR or INSTALL new as required.

springs, clips â loose, stuck, missing,
misassembled, clutch failed on
• SSD not functioning correctly, SSB • ACTIVATE solenoid using scan tool.
stuck on REFER to Output State Control (OSC)
Mode . GO to Pinpoint Test A . INSTALL
a new solenoid as required. REFER to
Solenoids .
Overdrive Clutch Assembly â Failed Off
• Friction â damaged, worn • INSTALL new as required.
• Return spring assembly â damaged • INSTALL new as required.

Direct Clutch Assembly â Failed On

• Return spring assembly â damaged • INSTALL new as required.


wiring harnesses, TCM , SSB Diagnosis (PC/ED) manual for diagnosis. GO to
failed, SSA stuck on and TR Pinpoint Test A and GO to Pinpoint Test D .
sensor


springs, clips â loose, stuck,
missing, misassembled, clutch
failed off
• Forward regulator and latch • REPAIR or INSTALL new as required.

valves, springs, clips â loose,
stuck, missing, misassembled,
clutch failed on
• SSB not functioning correctly, • ACTIVATE solenoid using scan tool. REFER to Output
SSA stuck on State Control (OSC) Mode . GO to Pinpoint Test A .
INSTALL a new solenoid as required. REFER to
Solenoids .
Direct Clutch Assembly â Failed Off


damaged
Forward Clutch Assembly â Failed On

damaged


wiring harnesses, TCM , SSC Diagnosis (PC/ED) manual for diagnosis. GO to
failed, SSB stuck on and TR Pinpoint Test A and GO to Pinpoint Test D .
sensor
TCS / O/D Cancel Switch
• Switch control circuit • REFER to Section 307-05A .

open/shorted, switch damaged

• Intermediate regulator and latch • REPAIR or INSTALL new as required.

clutch failed off


failed on
• SSC not functioning correctly, • ACTIVATE solenoid using scan tool. REFER to
SSB stuck on Output State Control (OSC) Mode . GO to Pinpoint
Test A . INSTALL a new solenoid as required. REFER
to Solenoids .
Intermediate Clutch Assembly â Failed
Off

damaged

damaged


failed, SSC stuck on and TR Pinpoint Test A and GO to Pinpoint Test D .
sensor



clutch failed on

failed off
• SSC not functioning correctly, • ACTIVATE solenoid using scan tool. REFER to
SSB stuck on Output State Control (OSC) Mode . GO to Pinpoint
to Solenoids .
Intermediate Clutch Assembly â Failed
On

damaged

damaged



wiring harnesses, TCM , SSA Diagnosis (PC/ED) manual for diagnosis. GO to
failed, SSB stuck on and TR Pinpoint Test A and GO to Pinpoint Test D .
sensor


failed on

clutch failed off
• SSA not functioning correctly, • ACTIVATE solenoid using scan tool. REFER to Output
SSB stuck on State Control (OSC) Mode . GO to Pinpoint Test A .
Solenoids .

damaged
Forward Clutch Assembly â Failed
Off


damaged


failed, SSD stuck on and TR Pinpoint Test A and GO to Pinpoint Test D .
sensor

• Overdrive regulator and latch • REPAIR or INSTALL new as required.

clutch failed on

failed off
• SSB not functioning correctly, • ACTIVATE solenoid using scan tool. REFER to
SSD stuck on Output State Control (OSC) Mode . GO to Pinpoint
to Solenoids .
Overdrive Clutch Assembly â Failed
On

• Return spring assembly â

damaged

damaged

• Electrical inputs/outputs, vehicle • RUN OBD . REFER to Powertrain

wiring harnesses, TCM , SSC Control/Emissions Diagnosis (PC/ED) manual
failed, SSB stuck on, TR sensor for diagnosis. GO to Pinpoint Test A and GO to
Pinpoint Test D .
Incorrect Pressures
• Line pressure • CHECK pressure at line pressure tap. CARRY

OUT Line Pressure Test. REFER to Special
Testing Procedures . SEE the Line Pressure
Chart for specifications. If not OK, CHECK
main control. REFER to Main Control Valve
Body .


missing, misassembled, stuck on



stuck off
• SSB or SSC not functioning • ACTIVATE solenoid using scan tool. REFER to
correctly Output State Control (OSC) Mode . GO to
Pinpoint Test A . INSTALL a new solenoid as
required. REFER to Solenoids .

damaged
Intermediate Clutch Assembly â Failed Off

damaged


vehicle wiring harnesses, Diagnosis (PC/ED) manual for diagnosis. GO to Pinpoint
TCM , SSC stuck on and TR Test A and GO to Pinpoint Test D .
sensor
Incorrect Pressures

Pressure Test. REFER to Special Testing Procedures . SEE

the Line Pressure Chart for specifications. If not OK, CHECK
main control valve body.

specification
• Gaskets and separator plate • INSTALL new as required.


misassembled, stuck on
correctly, stuck on Control (OSC) Mode . GO to Pinpoint Test A . INSTALL a
Intermediate Clutch Assembly â
Failed On

damaged
• Damaged â not holding • INSTALL new as required.

Planetary Carrier
• Damaged • INSTALL new as required.
Shift Concerns: Soft/Slipping 1-2 Shift (Automatic)

Solenoid Body
• Incorrect solenoid body • VERIFY solenoid body strategy data stored in the TCM .
strategy data stored in the DOWNLOAD new identification and strategy as necessary.

TCM REFER to Solenoid Body Strategy .

Incorrect Pressures

specification


binding, misassembled
new solenoid as required. Refer to Solenoids .

worn

damaged
Pump Assembly
• Component damaged • INSTALL a new pump assembly if required.


Solenoid Body
Incorrect Pressures

specification


loose, stuck, binding,
missing, misassembled

â loose, stuck, binding,
• Multiplex valve, springs, • REPAIR or INSTALL new as required.

clips â loose, stuck,
missing, binding
misassembled
• SSB or SSC not functioning • ACTIVATE solenoid using scan tool. REFER to Output State

worn

• Return spring assembly

â damaged

worn

â damaged

Solenoid Body

• VERIFY solenoid body strategy data stored in the TCM .
data stored in the TCM DOWNLOAD new identification and strategy as


stuck, binding, missing,
misassembled

misassembled
• SSD or SSB not functioning • ACTIVATE solenoid using scan tool. REFER to Output
correctly State Control (OSC) Mode . GO to Pinpoint Test A .
Solenoids .

Overdrive Clutch Assembly

damaged

damaged

Solenoid Body



misassembled


misassembled
• SSB or SSA not functioning • ACTIVATE solenoid using scan tool. REFER to Output
Solenoids .

damaged

damaged

Solenoid Body




misassembled

binding, missing, misassembled
• SSC or SSB not functioning • ACTIVATE solenoid using scan tool. REFER to Output
Solenoids .

damaged

damaged


Solenoid Body



misassembled

Solenoids .

damaged

damaged

Solenoid Body

• VERIFY solenoid body strategy data stored in the TCM
data stored in the TCM . DOWNLOAD new identification and strategy as


failed on

clutch failed off
Solenoids .

damaged


damaged

Solenoid Body

data stored in the TCM TCM . DOWNLOAD new identification and strategy
as necessary. REFER to Solenoid Body Strategy .


misassembled

binding, missing, misassembled,
clutch failed off
• SSB or SSD not functioning • ACTIVATE solenoid using scan tool. REFER to
correctly Output State Control (OSC) Mode . GO to Pinpoint
Test A . INSTALL a new solenoid as required.
REFER to Solenoids .


damaged

damaged

Solenoid Body
Incorrect Pressures
the Line Pressure Chart for specifications. If not OK,
CHECK main control valve body.

specification


loose, stuck, binding, missing,
misassembled


• SSB or SSC not functioning • ACTIVATE solenoid using scan tool. REFER to Output
INSTALL a new solenoid as required. REFER to Solenoids
.

damaged

damaged

Solenoid Body
Incorrect Pressures


specification



worn

damaged

Planetary Carrier
• Damaged • INSTALL new as required.
Shift Concerns: Harsh 1-2 Shift (Automatic)

Solenoid Body

Incorrect Pressures

specification


binding, misassembled

worn

damaged
Pump Assembly
• Component damaged • INSTALL a new pump assembly if required.


Solenoid Body
Incorrect Pressures

specification


misassembled

• Multiplex valve, springs, clips • REPAIR or INSTALL new as required.

â loose, stuck, missing,
binding misassembled
.


damaged

damaged

Solenoid Body



misassembled

misassembled
• SSD or SSB not functioning • ACTIVATE solenoid using scan tool. REFER to Output
Solenoids .


damaged

damaged

Solenoid Body



misassembled


misassembled
• SSB or SSA not functioning • ACTIVATE solenoid using scan tool. REFER to Output
Solenoids .

damaged

damaged

Solenoid Body




misassembled

Solenoids .

damaged

damaged

Solenoid Body




misassembled

Solenoids .

damaged

damaged


Solenoid Body

• VERIFY solenoid body strategy data stored in the TCM
data stored in the TCM . DOWNLOAD new identification and strategy as


failed on

clutch failed off
Solenoids .

damaged


damaged

Solenoid Body

data stored in the TCM TCM . DOWNLOAD new identification and strategy
as necessary. REFER to Solenoid Body Strategy .


misassembled

binding, missing, misassembled,
clutch failed off
• SSB or SSD not functioning • ACTIVATE solenoid using scan tool. REFER to
correctly Output State Control (OSC) Mode . GO to Pinpoint
Test A . INSTALL a new solenoid as required.
REFER to Solenoids .


damaged

damaged

Solenoid Body
Incorrect Pressures

specification


misassembled


.

damaged

damaged

Solenoid Body
Incorrect Pressures



specification



worn

damaged
Torque Converter Operation Concerns: No Apply

• Electrical inputs/outputs, vehicle • CARRY OUT Torque Converter Operation Test. REFER
wiring harnesses, TCM , TCC to Torque Converter Diagnosis . RUN OBD . REFER to
solenoid, TP sensor, TFT Powertrain Control/Emissions Diagnosis (PC/ED) manual
sensor, TSS sensor, OSS sensor for diagnosis. GO to Pinpoint Test A , GO to Pinpoint
and shorted shift solenoid Test B and GO to Pinpoint Test C .
Incorrect Pressures

Pressure Test. REFER to Special Testing Procedures .
SEE the Line Pressure Chart for specifications. If not OK,

• TCC control valve, springs, • REPAIR or INSTALL new as required.

clips â loose, stuck, missing,
misassembled
• TCC solenoid â not • ACTIVATE solenoid using scan tool. REFER to Output
functioning correctly State Control (OSC) Mode . GO to Pinpoint Test A .
Solenoids .
Turbine Shaft
• Seals â damaged, missing • INSTALL new as required.
• Holes â missing, plugged • REPAIR as required.

Pump Assembly
• Seals â damaged, missing • INSTALL new as required.
• Holes â missing, plugged • REPAIR as required.
• Torque converter hub bushing • INSTALL a new torque converter as required.

worn
• Torque converter worn • INSTALL a new torque converter as required.
Torque Converter Operation Concern: Always Applied/Stalls Vehicle

• Electrical • CARRY OUT Torque Converter Operation Test. REFER to Torque

inputs/outputs, Converter Diagnosis . RUN OBD . REFER to Powertrain
vehicle wiring Control/Emissions Diagnosis (PC/ED) manual for diagnosis. GO to
harnesses, TCM , Pinpoint Test A . REPAIR as required. CLEAR the DTCs. ROAD
TCC Solenoid TEST and RERUN OBD .

Main Controls

specification
• Gaskets and separator • REPAIR as required.

plate â damaged,
off location
• TCC regulator valve, • REPAIR or INSTALL new as required.

springs, clips â
missing,
misassembled
• TCC solenoid â • ACTIVATE solenoid using scan tool. REFER to Output State
not functioning Control (OSC) Mode . GO to Pinpoint Test A . INSTALL a new
correctly solenoid as required. REFER to Solenoids .
Torque Converter Operation Concern: Cycling/Shudder/Chatter

Powertrain Control
System
• Electrical • CARRY OUT Torque Converter Operation Test. REFER to Torque

inputs/outputs, Converter Diagnosis . RUN OBD . REFER to Powertrain
vehicle wiring Control/Emissions Diagnosis (PC/ED) manual for diagnosis. GO to
harnesses, TCM Pinpoint Test A . REPAIR as required. CLEAR the DTCs. ROAD
and TCC solenoid TEST and RERUN OBD .
Solenoid Body
• Incorrect solenoid • VERIFY solenoid body strategy data stored in the TCM . DOWNLOAD
body strategy data new identification and strategy as necessary. REFER to Solenoid Body
stored in the TCM Strategy .
• Transmission • Prior to carrying out this action, make sure all electrical diagnostics
fluid condition have been carried out. INSPECT transmission fluid condition. If burnt,
drain transmission fluid and converter. INSTALL new transmission
fluid and transmission fluid filter assembly. Bring vehicle to normal
operating temperature. CARRY OUT Transmission Drive Cycle Test.
RERUN OBD . If condition still exists, continue diagnostics.
Incorrect Pressures
• Line pressure • CHECK pressure at line pressure tap. CARRY OUT Line Pressure Test.
REFER to Special Testing Procedures . SEE the Line Pressure Chart for

specifications. If not OK, CHECK Main Control. REFER to Main

Control Valve Body .
Main Controls

torque
specification
• Gaskets and • REPAIR as required.

separator plate
â damaged, off
location
• TCC regulator • REPAIR or INSTALL new as required.

valve, springs,
clips â loose,
stuck, binding,
missing,
misassembled
• TCC solenoid • ACTIVATE solenoid using scan tool. REFER to Output State Control
â not (OSC) Mode . GO to Pinpoint Test A . INSTALL a new solenoid as
functioning required. REFER to Solenoids .
correctly
Turbine Shaft
• Seals â • INSTALL new as required.

damaged, missing
Torque Converter
• Torque converter • REFER to Torque Converter Contamination Inspection .

damaged
Pump Assembly
• Stator support • INSTALL new as required.

assembly â
worn, damaged
• Stator support • INSTALL new as required.

seals â worn,
damaged, leaking
Other Concerns: No Engine Braking In Manual Low Position

• No electrical concerns



specification

• Low/reverse regulator valve, • REPAIR or INSTALL new as required.

binding, missing,
misassembled
• Low/reverse latch valve, • REPAIR or INSTALL new as required.

binding, missing,
misassembled
• SSD not functioning correctly • ACTIVATE solenoid using scan tool. REFER to Output
State Control (OSC) Mode . GO to Pinpoint Test A .
Solenoids .

damaged
Other Concerns: Selector Lever Efforts High

Selector Lever Linkage (Internal, External)
• Damaged or out of adjustment • INSPECT for damage.

VERIFY selector lever

adjustment. REFER to
Section 307-05A .
Manual Control Lever
• External retaining pin â damaged, nut â loose, detent • REPAIR or INSTALL

springâ bent, damaged; or park mechanism â damaged, new as required.
incorrect lever used
• Manual valve â stuck • REPAIR or INSTALL

new as required.
• Bolts out of torque specification • TIGHTEN bolts to

specification.
Brake Shift Interlock
• Mechanically damaged • REFER to Section

307-05A .
• TR sensor indicating park • GO to Pinpoint Test D .
Other Concerns: External Leaks

• High transmission fluid level • CHECK transmission fluid level and

adjust as necessary. REFER to
Preliminary Inspection .
• Condition • CARRY OUT transmission fluid

condition check. REFER to
Preliminary Inspection .
Seals, Gaskets
• Leaks: converter, TSS sensor, halfshaft axles, • LOCATE source of leak. REPAIR as
gasket/seal manual lever, fluid level indicator, required.
main control cover, incorrect hub seal
Other
• Leaks: cooler fitting, pressure taps, transmission • LOCATE source of leak. REPAIR as
connector, transmission pan, cooler tubes, case required.
porosity, case cracked

• Vent â blocked damaged • REPAIR as required.
Other Concerns: Poor Vehicle Performance

• Electrical inputs/outputs, vehicle • RUN OBD . REFER to the Powertrain

wiring harnesses, TCM , TCC Control/Emissions Diagnosis (PC/ED) manual for
Solenoid, TP sensor, OSS sensor, diagnosis. GO to Pinpoint Test C . REPAIR as
MAF sensor, IAT sensors, internal required. CLEAR the DTCs. ROAD TEST and
wiring harness RERUN OBD .
• CARRY OUT Shift Point Road Test. REFER to

Shift Point Road Test and CARRY OUT Torque
Converter Operation Test. REFER to Torque
Converter Diagnosis .
Transmission Fluid
• Low level • CHECK transmission fluid level and adjust as

Verify Correct Shift Scheduling,
Engagements, Line Pressures and Stall
Speed
• GO to appropriate Diagnostic Routines per index.

Converter Clutch Always Applied
• GO to Routine 351.
Other Concerns: Noise/Vibration â Forward Or Reverse
NOTE: NVH symptoms should be identified using the diagnostic tools that are available. For a list of these
tools, an explanation of their uses and a glossary of common terms, refer to Section 100-04 . Since it is
possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a process of
elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system for
the symptom, refer back to Section 100-04 for the next likely system and continue diagnosis.



For Noises/Vibrations That Change With Engine Speed
• Converter components • LOCATE source of disturbance.

REPAIR as required.
• Transmission fluid level (low) â

pump cavitation.
• Pump assembly.
• Engine drive accessories
• Transmission fluid cooler tubes grounding out
• Flexplate
For Noises/Vibrations That Change With Vehicle Speed
• Engine mounts â loose or damaged • LOCATE source of disturbance.

REPAIR as required.
• Driveline concerns:
♦ Halfshaft shudder
♦ CV joints
♦ Suspension
♦ Modifications
• Output/halfshaft splines â worn or

damaged
• TSS sensor â incorrectly installed • REPAIR as required.

Other Noises/Vibrations
• Main controls â valve resonance • LOCATE source of disturbance.

REPAIR as required.
• Selector lever cable â vibration, grounding • LOCATE source of disturbance.

REPAIR as required.
• Transmission fluid cooler tubes â • LOCATE source of disturbance.

grounding REPAIR as required.
• ABS • REFER to Section 206-09 .
• Power steering pump • REFER to Section 211-02 .

Other Concerns: Engine Will Not Crank

• Electrical • CARRY OUT Torque Converter Operation Test. REFER to

inputs/outputs, vehicle Torque Converter Diagnosis . RUN OBD . REFER to the
wiring harnesses, TCM , Powertrain Control/Emissions Diagnosis (PC/ED) manual for
TR sensor diagnosis.
(Internal, External)
• Damaged or out of • INSPECT for damage. VERIFY selector lever cable adjustment.
Other Concerns: No Park Range

• Damaged or out of adjustment • INSPECT for damage.

VERIFY selector lever
cable adjustment.
REFER to Section
307-05A .
Park Mechanism
• Park brake pawl, park pawl return spring, park rod abutment, • REPAIR as required.
park pawl shaft, park pawl actuating rod, manual control
lever, manual lever detent spring â damaged
Other Concerns: Transmission Overheating

• No electrical
concerns


Transmission Fluid
• Incorrect • CHECK transmission fluid level. ADJUST as necessary. REFER to

transmission Preliminary Inspection .
fluid level
• Condition • CARRY OUT transmission fluid condition check. REFER to Preliminary

Inspection .
Transmission Fluid
Cooler Tubes
• Damaged, • REPAIR as required.

blocked,
reversed, leaking
Auxiliary Cooler
• Damaged, • REPAIR as required.

blocked,
restricted or
incorrectly
installed
Vehicle Concerns
Causing Engine
Overheating
• REFER to Section 303-03A .

Main Control Valve
Body
• Torque converter • REPAIR as required.

regulator
valve/spring â
stuck, damaged
• Torque converter • REPAIR as required.

control
valve/spring â
stuck, damaged
Torque Converter Not
Applying
• Seized converter • SEE Routine 250/350. INSPECT for damage. REPAIR as required.
one-way clutch
Excessive Towing Loads
• CHECK GVW .
Idle or Driveability
Concern

• REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.

Incorrect Clutch
Application or Oil
Pressure Control System
• CARRY OUT line pressure tests. REFER to Special Testing Procedures

and carry out shift point road test. REFER to Shift Point Road Test .
REPAIR as required. SEE the Line Pressure Chart, and Clutch
Application Chart for specifications. REPAIR as required.

GENERAL PROCEDURES Procedure revision date: 06/03/2011
Transmission Fluid Cooler Backflushing and Cleaning
Special Tool(s)
Turbo-Tank Heated Cooler Line Flusher

222-00004 or equivalent
Material
Item Specification
XT-10-QLVC

1 - Transmission fluid pressure tube (outlet)
2 - Transmission fluid return tube (inlet)
NOTE: Transmission fluid cooler backflushing will be carried out using the Turbo-Tank Heated Cooler Line
Flusher or equivalent. Follow the manufacturer's instructions included with the machine. Test the equipment
to make sure that a vigorous fluid flow is present before proceeding.
1. Check and top off fluid level of the Turbo-Tank Heated Cooler Line Flusher or equivalent tank with
transmission fluid.
2. Allow the fluid in the Turbo-Tank Heated Cooler Line Flusher or equivalent 15-30 minutes to heat up
to 60°C (140°F) before using.
Transmission Fluid Cooler Backflushing and Cleaning 3820

3. Install the line adapters into the transmission cooler lines.
4. NOTE: The TOP transaxle cooler tube on the transaxle is the pressure line.
Attach the Turbo-Tank Heated Cooler Line Flusher or equivalent red line to the transmission fluid
cooler pressure line quick disconnect fitting.
5. Attach the Turbo-Tank Heated Cooler Line Flusher or equivalent blue line to the transmission fluid
cooler return line quick disconnect fitting.
6. Follow the equipment instructions to purge the cooler lines and cooler prior to starting the flushing
procedure.
7. Allow the cooling system to backflush for 10-15 minutes, then flush the cooler in a normal flow
direction for an additional 10-15 minutes.
8. Clean the transaxle mounted fluid cooler tubes by hand.
Transmission Fluid Cooler Backflushing and Cleaning 3821

Transmission Fluid Drain and Refill
Material
Item Specification
XT-10-QLVC
NOTE: In order to completely clean the torque converter, this procedure needs to be carried out 3 times.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .
2. NOTE: If an internal problem is suspected, drain the transmission fluid through a paper filter. A
small amount of metal or friction particles may be found from normal wear. If an excessive amount of
metal or friction material ent, the transaxle will need to be overhauled.
Remove the transmission fluid drain plug and allow the transmission fluid to drain.
3. Install the transmission fluid drain plug.

Transmission Fluid Drain and Refill 3822

5. Start the engine and let it run for 3 minutes. Move the range selector lever into each gear position.
Repeat Steps 2, 3, 4 and 5 two more times.
6. After the transmission fluid has been changed a total of 3 times, using the scan tool with the engine
running, check and make sure that the transmission is at normal operating temperature 85-93°C
(185-200°F). Check and adjust the transmission fluid level and check for any leaks. If transmission
fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is
achieved.
P>

Transmission Fluid Exchange
Special Tool(s)
ATF Fluid Exchanger W/Power Steering

Fluid Exchanger
Material
Item Specification
XT-10-QLVC
NOTICE: Use transmission fluid specific for this transmission. Do not use any supplemental
transmission fluid additives or cleaning agents. The use of these products can cause internal
transmission components to fail, which will affect the operation of the transmission.
100-02 .
2. Use the ATF Fluid Exchanger W/Power Steering Fluid Exchanger to change the fluid.
3. Connect the ATF Fluid Exchanger W/Power Steering Fluid Exchanger to the transmission fluid
cooler tube after the transmission fluid cooler on the return tube. This will help remove any foreign
material trapped in the transmission fluid coolers.
4. Perform the transmission fluid exchange using the ATF Fluid Exchanger W/Power Steering Fluid
Exchanger. Follow the manufacturer's instructions included with the machine.
5. Once the transmission fluid exchange is completed, disconnect the ATF Fluid Exchanger W/Power
Steering Fluid Exchanger. Reconnect any disconnected transmission fluid cooler tubes.
6. Using the scan tool with the engine running, check and make sure that the transmission is at normal
operating temperature 85-93°C (185-200°F). Check and adjust the transmission fluid level and check
for any leaks. If transmission fluid ised, add transmission fluid in increments of 0.24L (0.5 pt) until
the correct level is achieved.
Transmission Fluid Exchange 3824

Transmission Fluid Exchange 3825

Torque Converter Contamination Inspection
Material
Item Specification
XT-10-QLVC
1. A new or remanufactured torque converter must be installed if one or more of the following
statements is true:
• A torque converter malfunction has been determined based on complete diagnostic
procedures.
• The torque converter stud or studs, impeller hub or bushing are damaged.
• The torque converter exhibits external discoloration (due to overheating).
• There is evidence of transmission assembly or fluid contamination due to the following
transmission or converter failure modes.
♦ Major metallic failure
♦ Multiple clutch plates or band failures
ficient component wear which results in metallic contamination
♦ Water or antifreeze contamination
2. If none of the above conditions are present, continue with the following fluid inspection.
3. Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or
through a paper filter.
4. Examine the fluid for contaminants. The fluid must be free of metallic contaminants.
5. NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque
converter or transmission damage will occur.
If the fluid passed inspection:
• drain the remaining fluid from the torque converter.

• using only the recommended transmission fluid, add 1.9L (2 qt) of clean fluid into the
converter and agitate by hand.
• thoroughly drain the fluid.
Torque Converter Contamination Inspection 3826

Torque Converter Contamination Inspection 3827

IN-VEHICLE REPAIR Procedure revision date: 06/03/2011
Transaxle Filler Tube

2 - Transaxle vent tube (part of 7A228)
3 13A506 Wiring harness retainer
4 N805320 Transaxle filler tube nut
6 - Transaxle filler tube O-ring
Removal
All vehicles
1. Remove the transaxle vent hose from the transaxle filler tui>
Vehicles equipped with a 3.0L engine
2. Disconnect the wiring harness retainer from the transmission fluid filler tube.
Transaxle Filler Tube 3828

All vehicles
3. Remove the transaxle filler tube nut.

• To install, tighten to 11 Nm (97 lb-in).
4. Pull and rotate the transaxle filler tube clockwise and remove the transaxle filler tube.
Installation
1. Inspect the O-ring seal on the transaxle filler tube for damage and install a new O-ring if needed.
Lubricate the O-ring seal with clean automatic transmission fluid.
2. To install, reverse the removal procedure.


Main Control Cover
Material
Item Specification
XT-10-QLVC
Ultra Silicone Sealant -
TA-29

1 14A464 Transaxle main harness electrical connector
2 9S318 Wiring harness retainer
4 N805320 Transmission fluid cooler tube nut
5 7H420 Transmission fluid cooler tube bracket
6 W500213 Main control cover bolt
7 W705619 Main control cover studbolt
100-02 .
2. Remove the screws and the underbody cover.
Main Control Cover 3831

3. Remove the Air Cleaner (ACL) assembly. For additional information, refer to Section 303-12A or
Section 303-12B .
4. Remove the transmission fluid drain plug and allow the transmission fluid to drain.

6. Disconnect the transaxle electrical connector.
7. Remove the transaxle electrical wiring harness retainers from the main control cover stud bolts.

8. Remove the 2 nuts, pull the transmission fluid cooler tube bracket and tubes away from the transaxle
and position it aside.
9. NOTE: Note the location of the stud bolts for assembly.
Remove the 8 bolts, 5 stud bolts and the main control cover.
Installation
1. Clean the main control cover sealing surface and inspect for damage.

2. Apply silicone to the main control sealing surface of the transaxle case.
3. Position the main control cover in place.
4. NOTICE: Inspect the main control-to-main control cover grommet to make sure that the seals is
on the inside of the main control cover. Transmission fluid leak will occur.
NOTE: Install the stud bolts in the locations noted during disassembly.
Tighten the 8 main control cover bolts and 5 stud bolts.
5. Position the transmission fluid cooler tube bracket and transmission fluid cooler tube assembly in
place and install the 2 nuts.

6. Connect the transaxle electrical wiring harness retainers to the main control cover stud bolts.
7. Connect the transaxle electrical connector.
8. Install the underbody cover and the screws.
9. Install the ACL assembly. For additional information, refer to Section 303-12A or Section 303-12B .
11. Start the engine and move the range selector lever into each gear position.
for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt)
until the correct level is achieved.


Manual Control Lever Shaft Seal
Special Tool(s)
Manual Lever Seal Installer

307-581
Material
Item Specification
XT-10-QLVC
TA-29

1 7E395 Selector lever cable
2 W708455 Manual control lever nut
3 7A256 Manual control lever
7 N805320 Transmission fluid cooler tube nuts
Manual Control Lever Shaft Seal 3837


9 W500213 Main control cover bolts
10 W705619 Main control cover studbolts
12 7G276 Transmission Range (TR) electrical connector
13 W711235 Manual valve detent spring bolt
14 7E332 Manual valve detent spring
15 7G100 Manual control shaft pin
16 7C493 Manual control shaft
Removal
100-02 .
Section 303-12B .

6. Disconnect the selector lever cable end from the manual control lever.

7. Remove the nut and the manual control lever.

12. Disconnect the Transmission Range (TR) sensor electrical connector.
13. Remove the bolt and the TR sensor detent spring.
14. Using a small pair of Vise Grips® or an equivalent suitable tool, remove and discard the TR sensor
locking pin.
15. Slide the manual shaft out of the transaxle case.

16. Using a suitable tool, remove the manual control lever shaft seal.
Installation
1. Using the Manual Lever Seal Installer, install a new manual control lever shaft seal.
2. Install the manual control lever shaft in the transaxle case and through the TR sensor.
3. Inspect the manual pin to make sure it is correctly installed in the manual valve. If it is not, pull the
manual control lever shaft out and correctly install the manual pin in the manual valve and position
the manual control lever shaft in place.
4. Using a suitable tool, install a new TR sensor roll pin.
5. Install the TR sensor detent spring and the bolt.


6. Connect the TR sensor electrical connector.
7. Clean the main control cover sealing surface.
10. NOTICE: Inspect the main control-to-main control cover grommet to make sure that the seal is


15. NOTICE: Make sure that when installing the manual control lever it is fully seated onto the
manual control lever shaft or damage to the manual control lever shaft will occur and the lever
will come loose.
NOTICE: Make sure to hold the manual control lever while tightening the manual control lever
nut or damage to the manual control lever and park components will occur.
Install the manual control lever and the nut.
16. Connect the selector lever cable end to the manual control lever with the manual control lever and
selector lever in DRIVE. Check selector lever cable adjustment. For additional information, refer to
Section 307-05A


Digital Transmission Range (TR) Sensor
Material
Item Specification
XT-10-QLVC
TA-29
Part
2 W708455 Manual control lever
nut
3 7A256 Manual control lever 4 14A464 Transaxle main
harness electrical
connector
7 N805320 Transmission fluid
cooler tube nuts
8 7H420 Transmission fluid
cooler tube bracket
Digital Transmission Range (TR) Sensor 3846

9 W500213 Main control cover

bolts
10 W705619 Main control cover
studbolts
12 7G276 Transmission Range
(TR) electrical
connector
13 W711235 Manual valve detent
spring bolt
14 7E332 Manual valve detent
spring
15 7G100 Manual control shaft
pin
17 7H155 TR sensor
Removal
100-02 .
Section 303-12B .


7. Remove the nut and the manual control lever.
10. Remove the transmission fluid cooler tube bracket nuts from the main control cover studs and
position the transmission fluid cooler tubes and bracket aside.

14. Using a small pair of Vise Grips® or an equivalent suitable tool, remove and discard the TR sensor
locking pin.

15. Remove the TR sensor in the following sequence.
1. Hold the TR sensor in place and slide the manual shaft outward until the manual shaft is out
of the transaxle case.
2. Remove the TR sensor from the transaxle, leaving the park pawl actuating rod attached to the
TR sensor.
Installation
1. Install the TR sensor.

1. Install the TR sensor and park pawl actuating rod in the transaxle case.
2. Install the manual shaft in the transaxle case through the TR sensor.
2. Inspect the manual pin to make sure it is correctly installed in the manual valve. If it is not, pull the
manual control lever shaft out and correctly install the manual pin in the manual valve and position
the manual control lever shaft in place.
3. Using a suitable tool, install a new TR sensor locking pin.

4. Install the TR sensor detent spring and the bolt.
9. NOTICE: Inspect the main control cover grommet to make sure that the seal is on the inside of
the main control cover. Transmission fluid leak will occur.
Install the main control cover 8 bolts and 5 stud bolts.

10. Position the transmission fluid cooler tube bracket and transmission fluid cooler tubes in place and
install the 2 nuts.

14. NOTICE: Make sure that when installing the manual control lever it is fully seated onto the
manual control lever shaft or damage to the manual control lever shaft will occur and the lever
will come loose.
NOTICE: Make sure to hold the manual control lever while tightening the manual control lever
Section 307-05A .


Solenoid Body Leadframe
Special Tool(s)
Pins, Leadframe Guide

307-636
Material
Item Specification
XT-10-QLVC
TA-29

Solenoid Body Leadframe 3855


10 W505513 Main control leadframe screw (5 required)
11 7G276 Main control leadframe
Removal
100-02 .
Section 303-12B .


11. Disconnect the Output Shaft Speed (OSS) sensor electrical connector.

12. Remove the main control cover grommet.
13. NOTICE: Be careful not to bend or twist the leadframe or the solenoid terminals when
removing the leadframe or damage can occur to the leadframe or the solenoids.
Remove the 5 screws and the leadframe from the solenoids by lifting it straight up evenly.
Installation
1. Install the Leadframe Guide Pins in the solenoid body to align the lead frame for installation.
2. Position the leadframe on the Leadframe Guide Pins and carefully install the leadframe by pushing
straight down into the solenoids.
3. Remove the Leadframe Guide Pins.

4. Install the 5 leadframe screws.
5. Connect the OSS sensor electrical connector.
7. Install the main control cover grommet.

the main control cover. Transmission fluid leak will occur.



Solenoids
Special Tool(s)

307-636
Material
Item Specification
XT-10-QLVC
TA-29

Solenoids 3863

11 7G276 Main control leadframe
12 7H111 Solenoid retaining pin (14 required)
13 7G136 Shift Solenoid A (SSA) (normally low)
14 7G383 Shift Solenoid B (SSB) (normally high)
15 7G136 Shift Solenoid C (SSC) (normally low)
16 7G383 Shift Solenoid D (SSD) (normally high)
17 7G484 Shift Solenoid E (SSE) (normally closed [OFF])
18 7G136 Torque Converter Clutch (TCC) solenoid (normally
low)
19 7G383 Line Pressure Control (LPC) solenoid (normally high)
Removal
100-02 .
Section 303-12B .

Solenoids 3864
Solenoids 3865
13. NOTICE: Be careful not to bend or twist the leadframe or the solenoid terminals when
removing the leadframe or damage can occur to the leadframe or the solenoids.
Remove the 5 screws and the leadframe from the solenoids by lifting it straight up evenly.
14. Using a paint pen, number the solenoids and solenoid body to clearly mark which solenoid was
removed from which bore in the solenoid body.
Solenoids 3866
15. Remove the solenoid retaining pin(s).
16. Remove the solenoid(s) from the solenoid body.
Installation
1. Inspect the solenoid(s) for damage.
2. If a new solenoid is not being installed, install the solenoid(s) into the bore from which it was
removed.
3. If installing a new Variable Force Solenoid (VFS), determine the base part number of the solenoid(s).
The Torque Converter Clutch (TCC) solenoid, Shift Solenoid A (SSA) and Shift Solenoid C (SSC)
are all normally low pressure solenoids. The Line Pressure Control (LPC) solenoid, Shift Solenoid B
(SSB) and Shift Solenoid D (SSD) are all normally high pressure solenoids. Shift Solenoid E (SSE) is
not a VFS , it is an ON/OFF solenoid.
Solenoids 3867
1 7G136 SSA (normally low)

2 7G383 SSB (normally high)
3 7G136 SSC (normally low)
4 7G383 SSD (normally high)
5 7G484 SSE (normally closed [OFF])
6 7G136 TCC solenoid (normally low)
7 7G383 LPC solenoid (normally high)
4. If installing a new LPC solenoid, SSB or SSD , note the color of the electrical terminal area of the
solenoid. The color will be blue or green and the solenoid can only be replaced with the same color
solenoid. If a new solenoid with that color is not available, install a new solenoid body, refer to
Solenoid Body Assembly in this section.
5. Determine the part number suffix by checking the solenoid service band number etched on the side of
the solenoid. The band number is the third digit on the side of the solenoid and will be a 1, 2, 3, 4 or
5. Use the following table to determine the part number suffix and match the new solenoid base part
number and suffix with the old solenoid. Install the solenoid in the solenoid body.
Solenoid Band Number Part Number Suffix

1 B
2 C
3 D
4 E
5 F
6. Install the solenoid retaining pin(s).
7. Install the Leadframe Guide Pins in the solenoid body to align the lead frame for installation.
Solenoids 3868
8. Position the leadframe on the Leadframe Guide Pins and carefully install the leadframe by pushing
straight down into the solenoids.
9. Remove the Leadframe Guide Pins.
Solenoids 3869
the main control cover, or a transmission fluid leak will occur.
Solenoids 3870
Solenoids 3871
Solenoids 3872
Material
Item Specification
XT-10-QLVC
TA-29

10 W302863 Main control-to-transaxle case bolt (long) (10 required)
11 W302862 Main control-to-transaxle case bolt (short) (12
required)

12 W520412 Main control nut

13 W500303 Solenoid body-to-valve body bolt (2 required)
15 7A100 Valve body assembly
Removal
100-02 .
Section 303-12B .



12. Remove the main control-to-main control cover grommet.
13. NOTICE: The main control should be handled with care or damage to the main control may
occur.
NOTE: Note the location of the different length bolts for assembly.
Remove the nut, 22 bolts and the main control.
14. Remove and discard the main control-to-transaxle case separator plate.

15. Remove the 2 bolts and separate the solenoid body assembly from the main control valve body.
16. Remove the 2 bolts and remove and discard the separator plate.
Installation
1. Install the new separator plate and the 2 separator bolts.

2. NOTE: If cleaning the main control assembly or inspecting the valves, refer to Main Control Valve
Body in this section. If installing a new main control assembly, continue with this procedure.
Install the solenoid body assembly onto the main control valve body. Install the 2 bolts.
3. Position the OSS and TR sensor wiring harnesses aside and install the new main control-to-transaxle
case separator plate.

4. NOTE: Make sure that the manual lever pin (part of the TR sensor) is correctly installed in the
manual valve.
Install the main control.
5. NOTICE: Make sure not to pinch the Output Shaft Speed (OSS) or Transmission Range (TR)
sensor wiring harnesses when installing the main control.
NOTE: Install the different length bolts in the locations noted during disassembly.
Install the main control stud nut and 22 main control valve body bolts. Tighten in a crisscross pattern.

8. Install the main control-to-main control cover grommet.

14. Connect the transaxle electrical wiring harness retainers to the main control cover studbolts.

21. If a new solenoid body is installed, the solenoid body strategy and solenoid body
identification will need to be updated. For additional information, refer to Solenoid Body
Strategy in this section

22. If a replacement transaxle assembly is being installed or a new solenoid body is installed, the
PCM will have to be reflashed with a new solenoid body strategy and identification data file.
For additional information, refer to Solenoid Body Strategy in this section.

Material
Item Specification
XT-10-QLVC
TA-29

3 14A163 Wiring harness retatd>
required)
Output Shaft Speed (OSS) Sensor 3883


13 7A100 Main control assembly
15 W713644 Output Shaft Speed (OSS) sensor bolt
16 7H103 OSS sensor
Removal
100-02 .
Section 303-12B .



12. Remove the main control-to-main control cover grommet.
occur.
14. Remove the main control-to-transaxle separator plate.

15. Remove the bolt and the OSS sensor.
Installation
1. Install the OSS sensor and the bolt.

2. Position the OSS and TR sensor wiring harnesses aside and install the main control-to-transaxle
separator plate.
manual valve.

5. Route the OSS sensor wiring harness and connect the electrical connector.

7. Install the main control-to-main control cover grommet.
on the inside of the main control cover or a transmission fluid leak will occur.
Install the 8 main control cover bolts and 5 stud bolts.

13. Connect the transaxle electrical wiring harness retainers to the main control cover studbolts.


Solenoid Body Assembly
Special Tool(s)

Material
Item Specification
XT-10-QLVC
TA-29

Solenoid Body Assembly 3892


required)
15 7A100 Valve body assembly
100-02 .
Section 303-12B .


7. Disconnect the transaxle electrical wiring harness retainers from the main control cover stud bolts.

occur.

15. Remove the 2 bolts and separate the solenoid body from the main control valve body.
Installation

2. NOTE: If cleaning the solenoid body assembly or inspecting the valves, refer to Solenoid Body
Assembly in this section. If installing a new solenoid body assembly, continue with this procedure.
Install the solenoid body onto the main control valve body. Install the 2 bolts.

3. Position the OSS and TR sensor wiring harnesses aside and install the new main control-to-transaxle
case separator plate.
manual valve.

6. Route the OSS sensor wiring harness and connect the electrical connector.

on the inside of the main control cover or a transmission fluid leak will occur.

21. Download a new solenoid body strategy to the PCM. For additional information, refer to Solenoid
Body Strategy in this section.

22. Using the scan tool, select Module Programming and Programmable Parameters under the tool box
icon and select Transmission. Follow the instructions displayed on the scan tool.
There are fields to enter the solenoid body 7-digit identification and 13-digit strategy recorded from
the solenoid body.
23. NOTICE: If the solenoid body information is not correct, transaxle damage or driveability
concerns can occur.
Enter the solenoid body identification and strategy.

The scan tool will verify that the numbers entered are valid and display a message if the information
is not valid.
The scan tool checks to see if the file is present on the scan tool. If the file is present, the technician
may proceed with downloading the file to the PCM. If the file is not present, the scan tool will need to
be connected to the Professional Technician Society (PTS) server to download the file ontohe scan
tool.
24. Verify that the file is present on the scan tool. If the file is present, go to Step 25. If the file is not
present, continue with this procedure.
25. Connect the scan tool to the PTS server.

The screen will display a progress bar when connecting to the network.
26. Follow the instructions on the network to download the strategy file to the scan tool.
The screen will display a progress bar when downloading the strategy file to the scan tool and display
a message if it is downloaded successfully.
27. If the scan tool cannot connect to the PTS server, download the file from www.motorcraft.com.
If the scan tool cannot download a strategy from the web site, a partial strategy will automatically be
downloaded.
28. Reconnect the scan tool to the vehicle.
29. Follow the instructions displayed on the scan tool.
30. If a new solenoid body was installed, compare the 7-digit identification and the 13-digit strategy fields
from the solenoid body to the replacement solenoid body tag provided with the solenoid body service
kit and place it over the existing identification tag.
The scan tool will automatically download the strategy file or partial strategy file to the PCM and will
display a progress bar while downloading. The scan tool will display a message when it is finished
downloading the data that states that the file was downloaded successfully.


Material
Item Specification
XT-10-QLVC

1 14A464 Turbine Shaft Speed (TSS) sensor electrical
connector
2 W500214 TSS sensor bolt
7M101 TSS sensor
Removal
100-02 .
2. Remove the 6 pin-type retainers and the LH front structure-to-subframe splash shield.
3. Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.
Turbine Shaft Speed (TSS) Sensor 3903

4. Remove the bolt and the TSS sensor.
Installation
1. Install the TSS sensor and the bolt.

2. Connect the TSS sensor electrical connector.
3. Install the LH front structure-to-subframe splash shield and the 6 pin-type retainers.


Halfshaft Seal - RH, All Wheel Drive (AWD)
Special Tool(s)
Installer, Halfshaft Oil Seal

308-431

307-428
Material
Item
XT-10-QLVC

1 1177 Seal assembly - halfshaft
2 7000 Transaxle
Removal
100-02 .
2. Remove the Power Transfer Unit (PTU). For additional information, refer to Section 308-07B .
3. Using a suitable awl, poke a small hole in the RH transaxle differential seal.
Halfshaft Seal - RH, All Wheel Drive (AWD) 3906

4. Using a suitable dent puller, remove the halfshaft seal.
Installation
1. Install a new halfshaft seal on the Halfshaft Oil Seal Installer.
2. Using the RH Halfshaft Oil Seal Installers, install the RH halfshaft seal onto the transaxle case.
3. Install the PTU . For additional information, refer to Section 308-07B .


Halfshaft Seal - RH, Front Wheel Drive (FWD)
Special Tool(s)
Handle
205-153 (T80T-4000-W)
Installer, Seal
307-626
Material
Item Specification
Automatic Transmid LV
XT-10-QLVC

1 1177 Seal assembly - halfshaft
2 3K183 Intermediate shaft
Removal
100-02 .
2. Remove the front RH halfshaft. For additional information, refer to Section 205-04 .
3. Using a suitable awl, poke a small hole in the halfshaft seal.
Halfshaft Seal - RH, Front Wheel Drive (FWD) 3909

Installation
1. Install a new halfshaft seal on the Seal Installer and Handle.
2. Using the Seal Installer and Handle, install the RH halfshaft seal.
3. Install the front RH halfshaft. For additional information, refer to Section 205-04 .


Halfshaft Seal - LH
Special Tool(s)
Handle
205-153 (T80T-4000-W)
Installer, Differential Seal

307-626
Material
Item Specification
XT-10-QLVC

1 3A428 LH halfshaft
Removal
100-02 .
2. Remove the front LH halfshaft. For additional information, refer to Section 205-04 .
3. Using a suitable awl, poke a small hole in the halfshaft seal.
Halfshaft Seal - LH 3912

Installation
1. Inspect the bushing surface on the LH halfshaft and the LH halfshaft bushing in the transaxle case for
damage or excessive wear. If the LH halfshaft or the LH halfshaft bushing shows signs of excessive
wear or damage, inspect the transaxle case for damage. Install a new LH halfshaft. Install a new LH
halfshaft bushing. For additional information, refer to Transaxle case bushing in this section.
• If the LH halfshaft or the LH halfshaft bushing shows signs of excessive wear or damage but
the transaxle case does not, install a new LH halfshaft. Install a new LH halfshaft bushing.
For additional information, refer to Transaxle case bushing in this section.
• If the transaxle case is damaged, install a new LH halfshaft. Install a new transaxle case. For
additional information, refer to Transaxle - 2.5L or Transaxle - 3.0L and Transaxle in this
section.
• If the bushing is not damaged or worn excessively, clean the area behind the seal and install a
new seal following this procedure.
2. Install a new halfshaft seal on the Differential Seal Installer and Handle.

3. Using the Differential Seal Installer and Handle, install the LH halfshaft seal.
4. Install the front LH halfshaft. For additional information, refer to Section 205-04 .

Transaxle Support Insulator - 3.0L
Special Tool(s)
Lifting Bracket, Engine

303-050 (T70P-6000)
Support Bar, Engine

303-F072
Universal Adapter Brackets

014-0001
Material
Item Specification
TA-25

1 W709234 Transaxle support insulator-to-frame rail bolts
2 W711873 Transaxle support insulator through bolt
4 W702434 Power Distribution Box (PDB) bolts
Transaxle Support Insulator - 3.0L 3915

5 N806543 PDB nut

6 180101 PDB
7 6F020 Transaxle support insulator
Removal
100-02 .
2. Remove the Air Cleaner (ACL) and the outlet pipe. For additional information, refer to Section
303-12B .
3. Remove the battery and battery tray. For additional information, refer to Section 414-01 .
4. Remove the 4 screws and position the LH fender splash shield aside.
6. Remove the lower 2 transaxle insulator-to-frame bolts.
7. Remove the cooling fan motor and shroud. For additional information, refer to Section 303-03A .
8. Install the Engine Lifting Bracket and Universal Adapter Bracket "L" hook on the LH side of the
engine.

9. Install the Engine Support Bar to support the engine.
10. Remove the transaxle support insulator through bolt.
11. Remove the wiring harness retainer from the transaxle support insulator and position the wiring
harness aside.
12. Disconnect the wiring harness retainer from the LH shock tower.
13. Remove the electrical connector bracket from the Battery Junction Box (BJB).
14. Remove the 2 bolts and the nut and position the BJB aside far enough to gain access to the top 2
transaxle support insulator bolts.

15. Remove the top 2 transaxle support insulator bolts and remove the transaxle support insulator.
Installation
1. Clean the rear transaxle support insulator bolts using a wire brush and apply new threadlock to the
threads.
2. Position the transaxle support insulator in place and install the upper 2 transaxle support insulator
bolts.
3. Install the lower 2 transaxle insulator-to-frame bolts.

4. Position the LH front structure-to-subframe splash shield in place and install the 6 pin-type retainers.
5. Position the LH splash shield in place and install the 4 screws.

6. Position the BJB and bracket in place and install the 2 bolts and the nut.
7. Install the electrical connector bracket on the BJB .
8. Connect the wiring harness retainer on the LH shock tower.
9. Position the wiring harness in place and install the retainer on the transaxle support insulator.
10. Install the through bolt.


11. Remove the Engine Support Bar.
12. Remove the Engine Lifting Bracket and the Universal Adapter Bracket "L" hook from the from the
LH side of the engine.
13. Install the cooling fan motor and shroud. For additional information, refer to Section 303-03A .
14. Install the battery and battery tray. For additional information, refer to Section 414-01 .
15. Install the ACL and the outlet pipe. For additional information, refer to Section 303-12B .

Transaxle Support Insulator - 2.5L
Special Tool(s)
Support Bar, Engine

303-F072
Material
Item Specification
TA-25

1 W709234 Transaxle support insulator-to-frame rail bolts
2 W711873 Transaxle support insulator through bolt
4 W702434 Power Distribution Box (PDB) bolts
5 N806543 PDB nut
6 180101 PDB
7 6F020 Transaxle support insulator
Removal

100-02 .
303-12A .
6. Remove the lower 2 transaxle insulator-to-frame bolts.
7. Using the Engine Support Bar, support the engine.
8. Remove the transaxle support insulator through bolt.

9. Remove the wiring harness retainer from the transaxle support insulator and position the wiring
harness aside.
10. Disconnect the wiring harness retainer from the LH shock tower.
11. Remove the electrical connector bracket from the Battery Junction Box (BJB).
12. Remove the 2 bolts and the nut and position the BJB aside far enough to gain access to the top 2
transaxle support insulator bolts.
13. Remove the top 2 transaxle support insulator bolts and remove the transaxle support insulator.
Installation
1. Clean the transaxle support insulator frame bolts using a wire brush and apply new threadlock to the
threads.

2. Position the transaxle support insulator in place and install the upper 2 transaxle support insulator
bolts.
3. Install the lower 2 transaxle support insulator bolts.

4. Position the LH front structure-to-subframe splash shield in place and install the 6 pin-type retainers.
5. Position the LH splash shield in place and install the 4 screws.
6. Position the BJB and bracket in place and install the 2 bolts and the nut.
7. Install the electrical connector bracket on the BJB .

8. Connect the wiring harness retainer on the LH shock tower.
9. Position the wiring harness in place and install the retainer on the transaxle support insulator.
10. Install the through bolt.

13. Install the ACL and the outlet pipe. For additional information, refer to Section 303-12A .


Transaxle Support Insulator - Anti-Roll

1 W711575 Roll restrictor bolts
2 6P082 Roll restrictor
Removal
All vehicles
100-02 .
3. Remove the Y-pipe. For additional information, refer to Section 309-00 .
All vehicles
4. Remove the 2 bolts and remove the roll restrictor.
Transaxle Support Insulator - Anti-Roll 3927

Installation
All vehicles
1. Position the roll restrictor in place and install the bolts.

2. Install the Y-pipe. For additional information, refer to Section 309-00 .
All vehicles


Transaxle Case Bushing
Special Tool(s)
Handle
205-153 (T80T-4000-W)
Installer, Seal
307-626
Step Plate
205-D015 (D80L-630-4) or equivalent
Remover, Transmission Extension Housing

Bushing
308-070 (T77L-7697-E)
Installer, Bushing
307-664
Material
Item Specification
XT-10-QLVC

2 7025 LH halfshaft bushing
Removal
1. Remove the fronH halfshaft seal. For additional information, refer to Halfshaft Seal - LH in this
section.
2. NOTE: Leave the drain plug out after the transmission fluid drains. The drain plug will need to
remain out to clean any debris from the damaged or worn bushing.
Remove the drain plug and drain the transmission fluid.
Transaxle Case Bushing 3930

3. Install the Step Plate in the differential carrier.
4. Using the Transmission Extension Housing Bushing Remover remove the LH halfshaft bushing.
5. Remove the Step Plate from the differential carrier.
Installation
1. Clean the halfshaft bushing area of the transaxle case.
2. Assemble the Handle and the Bushing Installer and install a new bushing on the Bushing Installer.
3. Using the Handle and the Bushing Installer, install a new bushing in the transaxle case.

4. Install a new halfshaft seal on the Seal Installer and Handle.
5. Using the Seal Installer and Handle, install the LH halfshaft seal.
6. Install a new LH halfshaft. For additional information, refer to Section 205-04 .

8. Fill the transaxle with clean transmission fluid. For additional information, refer to Transmission
Fluid Drain and Refill in this section.
9. Start the engine and let it run for 5 minutes.
10. Remove the transmission fluid drain plug and drain the transmission fluid a second time.


REMOVAL Procedure revision date: 06/03/2011
Transaxle - 2.5L
Special Tool(s)
Disconnect Tool, Transmission Cooler Line

307-569

300-OTC-1585AE
Retainer, Torque Converter

307-566
Support Bar, Engine

303-F072
Removal
NOTE: Refer to the Transmission Cooler Flushing Job Aid on the FMCDealer website.
100-02 .
303-12A .
5. Remove the 2 nuts and position the selector lever cable and bracket aside.
Transaxle - 2.5L 3934

6. Disconnect the wiring harness retainers from the main control cover studbolts.
7. Remove the 3 top bellhousing bolts.
8. NOTE: Use a steering wheel holding device such as Hunter® 28-75-1 or equivalent, to hold the
steering wheel.
Using a suitable holding device, hold the steering wheel in the straight-ahead position.
9. Remove the 2 nuts and the steering joint cover.
10. NOTICE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or
damage to the clockspring can occur. If there is evidence that the intermediate shaft has
rotated, the clockspring must be removed and recentered. For additional information, refer to
Section 501-20B .
Remove and discard the bolt and disconnect the steering column shaft from the steering gear.

11. If equipped, remove the 7 screws and the underbody cover.
12. NOTE: If transaxle disassembly or installation of a new transaxle is necessary, drain the transmission
fluid.
Remove the drain plug and allow the transmission fluid to drain.

14. NOTICE: Remove the steering gear/dash seal or damage to the seal may occur.
Release the 4 clips and slide the steering gear/dash seal off of the steering gear.
15. Remove the 2 roll restrictor bracket bolts.

16. Remove the 4 screws and position the RH fender splash shield aside.
17. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.
19. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
20. Remove the LH halfshaft and the intermediate shaft. For additional information, refer to Section
205-04 .
21. Disconnect the 2 in-line Electronic Power Assist Steering (EPAS) system electrical connectors at the
front of the subframe.

22. Detach the 2 EPAS system wiring harness pin-type retainers from the subframe.
23. Detach the EPAS system wiring harness pin-type retainer from the subframe under the LH fender
splash shield.
24. Remove the bolt and the EPAS system wiring harness ground from behind the RH splash shield.
Remove the nuts and separate the sway bar links from the struts.
26. Position the Powertrain Lift With Tilting Plate under the subframe assembly.

Remove the subframe bracket-to-body bolts.
Remove the subframe nuts and the subframe brackets.
Remove the front subframe nuts.
31. Install the Engine Support Bar and support the engine and transaxle.
32. Remove the transaxle support insulator through bolt and lower the transaxle 19 mm (0.748 in).

33. Remove the 3 nuts, the bolt and remove the transaxle support insulator bracket.
34. Remove the starter motor. For additional information, refer to Section 303-06 .
35. Remove the rubber insulator from the bellhousing.
36. NOTICE: Only rotate the engine in a clockwise direction or engine damage will occur.
NOTE: Mark one stud and the flexplate for assembly reference.
Remove and discard the 4 torque converter nuts.
37. Disconnect the transaxle main electrical connector.
38. Disconnect the Turbine Shaft Speed (TSS) electrical connector.

39. Remove the transmission fluid cooler tube secondary latches.
40. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes.
42. Remove the 3 rear torque converter housing bolts.
43. Remove the 4 front torque converter housing bolts.
44. Separate the transaxle from the engine and install the Torque Converter Retainer.

45. Remove the transaxle from the vehicle.
46. Remove the transmission fluid level indicator.
47. Remove the transmission fluid filler tube nut.
48. Remove the transaxle vent tube from the transaxle case and remove the transmission fluid filler tube.
49. Open the transmission fluid cooler tube retainers.
50. Remove the 2 secondary latches.

51. Using the Transmission Cooler Line Disconnect Tool, disconnect and remove the transmission fluid
cooler tubes from the transaxle.
52. Remove the 2 nuts and remove the transmission fluid cooler tube bracket.
53. If installing a new transaxle or overhauling the transaxle, the transmission fluid cooler will need to be
backflushed and cleaned. Carry out transmission fluid cooler backflushing and cleaning. For
additional information, refer to Transmission Fluid Cooler Backflushing and Cleaning in this section.
Clean the transaxle-mounted transmission fluid cooler tubes by hand.


Transaxle - 3.0L
Special Tool(s)

307-569
Engine Lifting Bracket Set

303-1140

303-050 (T70P-6000)
Powertrain Lift

307-566
Support Bar, Engine

303-F072
All vehicles
100-02 .
303-12B .
5. Remove the 2 nuts and position the selector lever cable and bracket aside.

6. Disconnect the wiring harness retainers from the main control cover stud bolts.
7. Disconnect the wiring harness retainer from the transmission fluid filler tube.
8. Remove the 3 upper torque converter housing bolts.
9. Remove the EGR valve and tube. For additional information, refer to Section 303-08B .
10. Remove the 2 bolts and the EGR valve bracket.

steering wheel. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
Section 501-20B .
15. NOTE: If transaxle disassembly or installation of a new transaxle is necessary, drain the transmission
fluid.
Remove the drain plug and allow the transmission fluid to drain.



22. Remove the LH halfshaft. For additional information, refer to Section 205-04 .
Front Wheel Drive (FWD) vehicles
23. Remove the exhaust flexible pipe. For additional information, refer to Section 309-00 .
24. Remove the intermediate shaft. For additional information, refer to Section 205-04 .
25. Disconnect the RH O2 sensor electrical connector.
26. Remove the 5 bolts and position the RH exhaust manifold heat shield aside.
27. Remove the Power Transfer Unit (PTU). For additional information, refer to Section 308-07B .
All vehicles
28. If equipped, remove the 2 bolts and the heat shield.

Remove the 2 roll restrictor bracket bolts.
30. Disconnect the 2 in-line EPAS system electrical connectors at the front of the subframe.
31. Detach the 3 wiring harness retainers from the LH front of the subframe.
32. Remove the bolt and the Electronic Power Assist Steering (EPAS) system wiring harness ground from
behind the RH splash shield.
33. NOTE: RH shown, LH similar.
Remove the nuts and separate the stabilizer bar links from the struts.

34. Position the Powertrain Lift under the subframe assembly.
Remove the subframe nuts and the subframe brackets.

39. NOTE: When installing the Engine Lifting Bracket Set, it will be easier to loosely install the upper
bolt first, then install the lower bolt.
Install the lower half of the Engine Lifting Bracket Set.
40. Install the upper half of the Engine Lifting Bracket Set.
41. NOTE: The washers are used to space the Engine Lifting Bracket far enough from the RH cylinder
head so that the Engine Support Bar can clear the RH valve cover. The washers used must fit on a 12
mm X 1.75 bolt.
Stack washers together to reach a 25.4 mm (1 in) to 28.575 mm (1.125 in) height.
42. NOTE: The bolt hole in the LH cylinder head that is used to install the Engine Lifting Bracket is a 12
mm X 1.75 thread.
NOTE: The bolt used to install the Engine Lifting Bracket must be between 65 mm (2.5 in) and 70
mm (2.75 in) long.
Assemble a 12 mm X 1.75 bolt with the Engine Lifting Bracket and the washers and install the bolt in
the threaded hole on the LH cylinder head with the lifting hook facing up.

43. Install the Engine Support Bar to support the engine.
44. Remove the transaxle support insulator through bolt and lower the transaxle 19 mm (0.748 in).
45. Remove the 3 nuts, the bolt and remove the transaxle support insulator bracket.
46. Remove the inspection cover.

47. NOTE: Mark one stud and the flexplate for assembly reference.
Remove and discard the 4 torque converter nuts.
48. Disconnect the transaxle main electrical connector.
49. Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.

53. Remove the 2 bolts, 2 nuts and the stud from the front of the torque converter housing.
54. Remove the 2 back torque converter housing bolts and remove the transaxle from the dowel pins.
55. Separate the transaxle from the engine and install the Torque Converter Retainer.
56. Remove the transaxle from the vehicle.
57. Remove the transmission fluid level indicator.
58. Remove the transmission fluid filler tube nut.

59. Remove the transaxle vent tube from the transaxle case and remove the transmission fluid filler tube.
61. Remove the 2 secondary latches.
63. Remove the 2 nuts and remove the transmission fluid cooler tube bracket.

64. If installing a new transaxle, the transmission fluid cooler will need to be backflushed and cleaned.
Carry out transmission fluid cooler backflushing and cleaning. For additional information, refer to
Transmission Fluid Cooler Backflushing and Cleaning in this section.

DISASSEMBLY Procedure revision date: 06/03/2011
Transaxle
Special Tool(s)
Handle, Torque Converter

307-091 (T81P-7902-C)
Holding Fixture
307-625
Installer, Wheel Speed Sensor Ring

206-084/2
Remover, Roll Pin

211-061 (T78P-3504-N1)

307-566
1. Install the Holding Fixture 307-625.
2. Using the Holding Fixture 307-625, install the transaxle on a bench-mounted holding fixture.
3. Remove the Torque Converter Retainer 307-566.
Transaxle 3958
4. Install the Torque Converter Handle 307-091.
5. NOTICE: The torque converter is heavy. Be careful not to drop it or damage will result.
Using Torque Converter Handle 307-091, remove the torque converter from the transaxle.
Remove the 13 bolts and the main control cover.
Transaxle 3959
9. Remove the solenoid body-to-main control cover grommet.
10. NOTE: Note the location of the short and long main control bolts for reassembly.
Remove the nut and the 22 Torx bolts and remove the main control assembly.
12. Remove and discard the forward (1, 2, 3, 4) clutch and low/reverse clutch transaxle case-to-center
support seals.
1. Forward (1, 2, 3, 4) clutch transaxle case-to-center support seal.
2. Low/reverse clutch transaxle case-to-center support seal.
13. Remove the internal cooler bypass spring, sleeve and valve.
Transaxle 3960
14. Remove the bolt and the Turbine Shaft Speed (TSS) sensor.
16. Remove the bolt and the OSS sensor.
Remove the 17 torque converter housing bolts.
Transaxle 3961
18. Using a suitable tool, pry the torque converter housing loose from the transaxle case.
19. Remove the torque converter housing from the transaxle case.
20. Remove the No. 15 differential thrust bearing.
21. Remove the differential.
22. Remove the differential planetary sun gear.
Transaxle 3962
23. Remove the No. 13 thrust washer.
24. Remove the No. 11 drive sprocket thrust bearing.
25. Simultaneously remove the drive and driven sprockets and the chain.
Transaxle 3963
26. Remove the No. 12 driven sprocket thrust bearing.
27. Remove the No. 10 front sun gear and shell assembly thrust bearing.
28. Remove the 2 bolts and the transmission fluid reservoir.
Transaxle 3964
29. Remove the 2 bolts and the transmission fluid baffle.
30. Remove the park pawl pin and spring.
31. Remove the park pawl.
32. NOTE: The forward (1, 2, 3, 4) clutch snap ring is beveled. The beveled side of the snap ring goes up
(flat side down).
NOTE: The forward (1, 2, 3, 4) clutch snap ring gap faces the front of the transmission.
Transaxle 3965
Remove the forward (1, 2, 3, 4) clutch snap ring.
33. Remove the forward (1, 2, 3, 4) clutch pressure plate, clutch assembly and wave spring.
34. Remove the front sun gear and shell assembly.
35. Remove the front planetary carrier/rear ring gear assembly.
36. Remove the No. 7 and No. 8 thrust bearings.

1. No. 7 thrust bearing
Transaxle 3966
37. Remove the center planetary carrier/front ring gear assembly.
38. Remove the center planetary sun gear.
39. Remove the No. 5 and No. 6 thrust bearings.

40. Remove the center support assembly.
41. Remove the rear planetary carrier/center ring gear assembly.
Transaxle 3967
42. Remove the low/reverse wave spring, clutch pack and pressure plate.
43. Remove the low One-Way Clutch (OWC).
44. NOTE: The intermediate (2, 6) clutch is removed with the rear planetary sun gear and shell assembly.
Remove the rear planetary sun gear and shell assembly and remove the intermediate (2, 6) clutch from
the assembly.
45. Remove the pressure plate and the wave spring.
Transaxle 3968
46. Remove the No. 3 thrust bearing.
47. Remove the overdrive/direct clutch assembly.
48. NOTE: If the No. 1 thrust bearing is stuck to the overdrive/direct clutch assembly, remove the No. 1
thrust bearing from the overdrive/direct clutch assembly.
Remove the No. 1 thrust bearing.
49. Remove the intermediate (2, 6) clutch apply ring.
50. Remove the 3 bolts and the clutch support tower.
Transaxle 3969
51. NOTE: Note the location of the snap ring gap for assembly.
Remove the intermediate (2, 6) clutch return spring snap ring.
52. NOTE: Note the position of the return spring for assembly.
Remove the intermediate (2, 6) clutch return spring.
53. NOTE: Note the position of the intermediate clutch piston for assembly.
Remove the intermediate (2, 6) clutch piston.
Transaxle 3970
54. Remove and discard the 5 clutch feed seals.
55. Remove the nut and the manual control lever from the manual shaft.
56. NOTICE: Do not drive the roll pin through the manual shaft. The roll pin will contact the
transaxle case causing damage to the transaxle case.
Using Roll Pin Remover 211-061, pull the roll pin out of the manual shaft.
57. Remove the manual shaft.
Transaxle 3971
58. Remove the TR sensor and the park pawl actuator rod and remove the park pawl actuator rod from the
TR sensor.
59. Using a suitable tool, remove and discard the manual shaft seal.
60. Using a suitable tool, remove and discard the LH halfshaft seal.
61. NOTE: Press the bushing out of the transaxle case from the outside to the inside so that the transaxle
case rests on a flat surface.
Using the Wheel Speed Sensor Ring Installer 206-084/2 and a suitable press, remove and discard the
LH transaxle case bushing from the transaxle case.
62. Remove the 2 bolts and the oil baffle from the torque converter housing.
Transaxle 3972
63. Remove the 8 bolts and the pump and filter assembly.
64. Remove the differential ring gear snap ring.
65. Remove the differential ring gear.
66. Using a suitable tool, remove and discard the RH halfshaft seal.
Transaxle 3973
Transaxle 3974
SUBASSEMBLIES
Final Drive Carrier and Differential Assembly
Disassembly
1. Using a suitable tool, drive the roll pin out of the differential. Discard the roll pin.
2. Remove the differential pin.
3. NOTICE: Do not mix up the washers from the side or spider gears that they were originally
assembled with. Assembly of the differential with the wrong washcan cause excessive wear to
the differential carrier, spider or side gears.
Rotate the side gears along with the spider gears and remove the side gears and the spider gears.
1. Side gear
2. Spider gear
4. Remove the washers from the side and spider gears, but keep the washers with the gear that it was
originally assembled with.
Final Drive Carrier and Differential Assembly 3975

Assembly
1. Clean and inspect the side gears and spider gears and washers for damage or excessive wear and
install new components as necessary.
2. Clean and inspect the differential pin for damage or excessive wear and install new if necessary.
3. Clean and inspect the differential for damage and install new if necessary.
1. Inspect the thrust bearing surfaces.
2. Inspect the differential planetary gear teeth.
3. Inspect the differential planetary gear teeth to be sure they spin freely and do not move back
and forth or side to side excessively.

4. Clean and inspect the differential sun gear for damage or excessive wear and install new if necessary.
5. NOTICE: Do not mix up the washers from the side or spider gears that they were originally
assembled with. Assembly of the differential with the wrong washers can cause excessive wear
to the differential carrier, spider or side gears.
Install the washers on the side or spider gears that they were removed from.
6. Position the side gears in the differential carrier.
7. Place the spider gears in the differential carrier and rotate the side gears with the spider gears until the
differential pin hole lines up to the holes in the spider gears.

8. Install the differential pin with the roll pin holes aligned.
9. Using a suitable tool, install a new roll pin.

SUBASSEMBLIES
Pump and Filter Assembly
Special Tool(s)
Collet, 3/4 Inch to 7/8 Inch

303-D019 (D80L-100-Q)
Installer, Converter Seal

307-627
Seal Installer, Turbine Shaft

307-634
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
XT-10-QLVC
Pump Assembly

1 7A103 Pump housing
2 - Main pressure regulator valve assembly
3 -
Pump and Filter Assembly 3979

Torque Converter Clutch (TCC) control valve

assembly
Disassembly
1. NOTE: Note the orientation of the fluid filter to the fluid pump.
Remove the filter from the pump.
1. Rotate the filter 90 degrees clockwise.

2. Pull the filter out pump.
2. Remove the magnet from the filter.
3. Assemble the Slide Hammer 100-001 and 3/4 Inch to 7/8 Inch Collet 303-D019 and remove and
discard the input shaft seal.
4. Remove the pump-to-torque converter housing seal.
Pump Assembly 3980

5. If equipped, remove the torque converter hub seal snap ring.
6. Using a suitable dent puller, remove the torque converter hub seal.
7. Position the pump assembly in the torque converter housing and install 2 pump-to-torque converter
housing bolts hand-tight.
8. Loosen the 23 pump bolts.
9. Remove the 2 bolts and the pump from the torque converter housing.
Pump Assembly 3981

10. Remove the 23 pump bolts and separate the pump halves.
11. NOTE: The dot on the inner pump gear faces up.
Remove the pump gears.
12. Compress the main pressure regulator valve spring with a screwdriver and remove the retainer with a
magnet.
13. Install an M4 bolt in the valve and remove the main pressure regulator valve assembly.
14. Compress the Torque Converter Clutch (TCC) control valve spring with a screwdriver and remove the
retainer with a magnet.
Pump Assembly 3982

15. Remove the TCC control valve assembly.
Assembly
1. Clean and inspect the components of the pump assembly for wear or damage. Inspect the fluid
drained from the pump for excessive metal or foreign material. If excessive wear, damage or
excessive metal is found, replace the fluid pump as an assembly.
2. NOTE: TCC control valve retainer shown assembled in the pump body, main pressure regulator
valve retainer similar.
Assemble the TCC control valve and main pressure regulator valve and install the valves in the pump.
Compress the valve springs with a screwdriver and install the retainers.
3. NOTE: The dot on the inner pump gear faces up.
Install the pump gears.
Pump Assembly 3983

4. Position the stator support on the pump housing and install the 23 bolts hand-tight.
5. Install the pump assembly in the torque converter housing and install 2 bolts hand-tight.
6. Tighten the 23 pump housing bolts.

7. Remove the 2 bolts and the pump assembly from the torque converter housing.
8. Install a new torque converter hub seal on Converter Seal Installer 307-627.
9. Using the Converter Seal Installer 307-627, install a new torque converter hub seal.
Pump Assembly 3984

10. If equipped, install the torque converter hub seal snap ring.
11. Install a new pump-to-torque converter housing seal.
12. Install a new turbine shaft seal on Turbine Shaft Seal Installer 307-634.
13. Using Turbine Shaft Seal Installer 307-634, install the turbine shaft seal.
14. Install a new O-ring on a new filter and lubricate it with clean automatic transmission fluid.
Pump Assembly 3985

15. Install the magnet on the filter.
16. Install the filter.

1. Position the filter in the pump.
2. Rotate the filter counterclockwise 90 degrees.
Pump Assembly 3986

Pump Assembly 3987

SUBASSEMBLIES
Clutch Support Tower
Special Tool(s)
Input Shaft Support Seal Installer (Back

Plate, Multiple Rings)
307-578 (includes 307-578/1, 307-578/2
and 307-578/3)
Disassembly
1. Using a suitable tool, remove and discard the 4 Teflon® seals.
2. Clean and inspect the clutch support towerdamage. Install a new clutch support tower if damaged.
Assembly
1. Install the Input Shaft Support Seal Installer 307-578/3 on the clutch support tower and adjust the
Input Shaft Support Seal Installer to align the bottom edge of the tool with the top edge of the bottom
Teflon® seal groove.
2. Install a new Teflon® seal on the Input Shaft Support Seal Installer 307-578/3.
Clutch Support Tower 3988

3. Install the Input Shaft Support Seal Installer 307-578/2 over 307-578/3. Using the Input Shaft Support
Seal Installer 307-578/2, slide the Teflon® seal over the clutch support tower and into the groove.
4. Remove the Input Shaft Support Seal Installer 307-578/2 and 307-578/3.
• Repeat Steps 1 through 4 for the other 3 Teflon® seals.
5. Install the Input Shaft Support Seal Installer 307-578/1 on the clutch support tower to size the 4
Teflon® seals.


SUBASSEMBLIES

1 W500303 Solenoid body-to-valve body bolt
3 7A100 Main control valve body
4 7E195 Check balls
5 7J191 Solenoid damper (Shift Solenoid A (SSA))
6 7C389 Manual valve
7 7G473 Solenoid pressure regulator valve assembly
8 7G179 Clutch bypass valve
9 7G307 Torque Converter Clutch (TCC) regulator valve
10 7B200 Control pressure regulator
11 7D102 Direct (3, 5, R) clutch regulator valve
12 7D102 Intermediate (2, 6) clutch regulator valve

13 7D102 Forward (1, 2, 3, 4) clutch regulator valve

14 7J187 Forward (1, 2, 3, 4) clutch latch valve
15 7D102 Low reverse/overdrive (4, 5, 6) clutch regulator valve
Disassembly
1. Remove the 2 bolts and separate the solenoid body from the valve body.
3. Remove the 3 check balls and the damper.

1. Check balls
2. Solenoid damper
4. Remove the manual valve.

5. NOTICE: Remove the valves by tapping the valve body on the palm of the hand to slide the
valves out of the bores or by threading a 4-mm bolt into the valves and pulling them out. It may
be necessary to remove the valves and springs using a pick. If it is necessary to use a pick, use
extreme caution to prevent damaging the valves or valve bores. If necessary, disassemble parts
of the main control valve body in small groups. Take special care when handling the main
control components, since they are the most precise and delicate parts of the transaxle. Neatly
arrange the parts as they are removed to avoid mixing similar pieces.
NOTICE: Do not stone or polish any valves or damage to the valves can occur. If the valves do
not move freely, install a new assembly.
NOTE: The bypass valve is held in with a spring-loaded retainer. Be careful not to lose the retainer
when removing it.
Compress the valve springs with a screwdriver and remove the retainers with a magnet. Use a pick to
remove the bypass valve retainer. Remove the individual valves and springs from the main control
valve body by tapping the valve body on the palm of the hand to slide the valves out of the bores. If
needed, use a 4-mm bolt to thread into the valves to remove the valves. See the Valve Body
illustration for valve and spring locations. Clean valves, springs and main control valve body.
Assembly
1. NOTICE: Do not stone or polish any valves or damage to the valves can occur. If the valves do
not move freely during assembly, install a new valve body.
Install the valve body valves, springs and retaining clips in the main control valve body. See the
Valve Body illustration at the beginning of this procedure for valve and spring locations.

2. Install the manual valve in the valve body.
3. Install the 3 check balls and the damper.

1. Check balls
2. Solenoid damper

5. For disassembly and assembly of the solenoid body, refer to Solenoid Body Assembly in this section.

6. Position the solenoid body assembly on the valve body and install the 2 bolts.

SUBASSEMBLIES
Solenoid Body Assembly
Special Tool(s)

307-636
Solenoid Body
Part
1 W500303 Solenoid body-to-valve body bolt
3 N605770 Solenoid body-to-valve body separator plate bolt (2
required)
4 7Z490 Solenoid body-to-valve body separator plate

5 7K221 Circuit filter

7 W505513 Leadframe screw (5 required)
8 7G276 Leadframe
9 7H111 Solenoid retaining pin (14 required)
10 7J187 Direct (3, 5, R) clutch latch valve
11 7J187 Intermediate (2, 6) clutch latch valve
12 7J187 Low reverse/overdrive (4, 5, 6) clutch latch valve
13 7G383 Line Pressure Control (LPC) solenoid
14 7G136 Shift Solenoid C (SSC)
15 7G136 Torque Converter Clutch (TCC) solenoid
16 7G484 Shift Solenoid E (SSE) ON/OFF solenoid
17 7G136 Shift Solenoid A (SSA)
18 7G383 Shift Solenoid B (SSB)
19 7G383 Shift Solenoid D (SSD)
Disassembly
1. If not previously done, remove the 2 bolts and separate the solenoid body from the valve body.
3. Remove and discard the circuit filter.
Solenoid Body 3997

4. Compress the valve springs with a screwdriver and remove the retainers with a magnet. Remove the
individual valves and springs from the solenoid body by tapping it on the palm of the hand to slide the
valves out of the bores. See the Solenoid Body illustration at the beginning of this procedure for valve
and spring locations.
5. NOTICE: Be careful not to bend or twist the solenoid body leadframe or the solenoid terminals
when removing the leadframe or damage can occur to the leadframe or the solenoids.
Remove the 5 screws and carefully remove the leadframe from the solenoids by lifting it straight up
evenly.
6. NOTICE: The solenoids are calibrated from the factory and are not all the same. Failure to
mark the solenoids to the ports they were originally in can result in mixing the solenoids and
can cause damage to the transaxle or a harsh shift.
Using a paint marker, number the solenoids and the solenoid body to correspond with the ports from
which the solenoids are located in the solenoid body.
Solenoid Body 3998

7. Remove the solenoid retaining pins.
8. Remove the solenoids from the solenoid body.
Assembly
1. NOTICE: Be careful not to wash the numbers from the solenoids or the solenoid body. Failure
to install the solenoids in the ports they were originally in can result in damage to the transaxle
or a harsh shift.
NOTICE: Do not stone or polish any valves or damage to the valves can occur. If the valves do
not move freely during assembly, install a new solenoid body.
Clean and inspect the solenoid body, solenoids and valve assemblies for damage. Inspect the solenoid
screens for debris that may restrict fluid flow through the screen.
2. NOTICE: The solenoids are calibrated from the factory and are not all the same. Failure to
install the solenoids in the ports they were originally in can result in damage to the transaxle or
a harsh shift.
If new solenoid(s) are not being installed, position the solenoids in the solenoid body ports from
which their numbers correspond.
Solenoid Body 3999

3. If installing a new Variable Force Solenoid (VFS), determine the base part number of the solenoid(s).
The Torque Converter Clutch (TCC) solenoid, Shift Solenoid A (SSA) and Shift Solenoid C (SSC)
are all normally low pressure solenoids. The Line Pressure Control (LPC) solenoid, Shift Solenoid B
(SSB) and Shift Solenoid D (SSD) are all normally high pressure solenoids. Shift Solenoid E (SSE) is
not a VFS ; it is an ON/OFF solenoid.

1 7G136 SSA (normally low)
2 7G383 SSB (normally high)
3 7G136 SSC (normally low)
4 7G383 SSD (normally high)
5 7G484 SSE (normally closed [OFF])
6 7G136 TCC solenoid (normally low)
7 7G383 LPC solenoid (normally high)
4. If installing a new LPC solenoid, SSB or SSD , note the color of the electrical terminal area of the
solenoid. The color will be blue or green and the solenoid can only be replaced with the same color
solenoid. If a new solenoid with that color is not available, install a new solenoid body, refer to
Solenoid Body Assembly in this section.
5. Determine the part number suffix by checking the solenoid service band number etched on the side of
the solenoid. The band number is the third digit on the side of the solenoid and will be a 1, 2, 3, 4 or
5. Use the following table to determine the part number suffix and match the new solenoid base part
number and suffix with the old solenoid. Install the solenoid in the solenoid body.
Solenoid Band Number Part Number Suffix

1 B
2 C
3 D
4 E
Solenoid Body 4000

5 F
6. Install the solenoid retaining pins.
7. Install Leadframe Guide Pins 307-636 in the solenoid body to align the leadframe for installation.
8. Position the leadframe on the guide pins and carefully install the leadframe by pushing it straight
down into the solenoids.
9. Remove Leadframe Guide Pins 307-636.
Solenoid Body 4001

11. NOTICE: If the valves do not move freely during assembly, install a new solenoid body. Failure
to install a new solenoid body can result in a harsh shift or damage to the transaxle.
Install the solenoid body valves, springs and retaining clips in the solenoid body. See the Solenoid
Body illustration at the beginning of this procedure for valve and spring locations.
12. Install the circuit filter.
13. Install the new separator plate and the 2 bolts.

14. If not previously done, refer to Main Control Valve Body in this section for disassembly and
assembly of the valve body.
15. Position the solenoid body assembly on the valve body and install the 2 bolts.
Solenoid Body 4002

Solenoid Body 4003

SUBASSEMBLIES
Planetary Gearsets And Chain Drive Parts
1. Clean and inspect the front planetary sun gear and shell assembly for damage or wear and install new,
as necessary.
• Gear teeth
• Shell-to-clutch pack surfaces
• Thrust bearing surfaces
2. Clean and inspect the front planetary gear carrier/rear ring gear assembly for damage or excessive
wear and install new, as necessary.
• Pinion gear teeth
• Pinion gear surfaces
• Pinion gear bearings
• Spline teeth
• Thrust bearing
• Thrust bearing surfaces <
• Ring gear teeth
3. Clean and inspect the center planetary gear carrier/front ring gear assembly for damage or excessive
Planetary Gearsets And Chain Drive Parts 4004


• Spline teeth
• Ring gear teeth
4. Clean and inspect the center planetary sun gear for damage or excessive wear and install new, as
necessary.
• Sun gear teeth
• Spline teeth
5. Clean and inspect the rear planetary gear carrier/center ring gear assembly for damage or excessive
• Spline teeth
• Thrust bearing
• Ring gear teeth

6. Clean and inspect the rear planetary sun gear and shell assembly for damage or wear and install new,
if necessary.
• Sun gear teeth
• Shell-to-clutch pack surfaces
• Bearing surfaces
7. Remove the drive chain from the drive and driven sprockets.
8. Clean and inspect the drive chain for damage or excessive wear and install new, if necessary.
• Check the drive chain for wear, stretching or tightness of the chain links.
• Check that the chain moves freely.

9. Inspect the driven sprocket for damage or excessive wear and install new, if necessary.
• Chain teeth
• Spline teeth
• Bearing
10. Remove the snap ring and remove the drive sprocket from the front planetary hub/park gear assembly.
11. Inspect the drive sprocket for damage or excessive wear and install new, if necessary.
• Chain teeth
• Spline teeth
• Thrust washer surface
12. Inspect the front planetary hub/park gear assembly for damage or excessive wear and install new, if
necessary.
• Park gear teeth
• Spline teeth

• Thrust washer surface
• Thrust bearing surface
• Bearing surfaces
• Needle bearing
13. Install the drive sprocket on the front planetary hub/park gear assembly and install the snap ring.
14. Install the drive chain on the drive and driven sprockets.


SUBASSEMBLIES
Low One-Way Clutch
1. NOTICE: Do not clean in water or with water-based solvents. Damage to the component may
occur.
NOTE: The low One-Way Clutch (OWC) should not be disassembled.
Clean and inspect the low OWC for cracks and damaged splines. The internal splined section should
rotate clockwise and lock when rotated counterclockwise. If any damage is found or the clutch does
not rotate or lock, install a new low OWC .
2. Inspect the intermediate () clutch surface for damage. If the surface is burned or worn excessively,
install a new OWC .
Low One-Way Clutch 4010

SUBASSEMBLIES
Overdrive/Direct Clutch Assembly
Special Tool(s)
Compressor, Forward/Intermediate Spring

307-584 (includes 307-584/1 and
307-584/2)
Compressor, Overdrive Clutch, Balance
Piston and Direct Clutch
307-589 (includes 307-589/1 and
307-589/2)
Dial Indicator Gauge With Holding Fixture
100-002 (TOOL-4201-C)

307-578 (includes 307-578/1, 307-578/2
and 307-578/3)
Material
Item Specification
XT-10-QLVC
Disassembly
1. Remove the input shaft snap ring.
2. Remove the input shaft.
Overdrive/Direct Clutch Assembly 4011

3. Remove thverdrive (O/D) (4, 5, 6) clutch hub.
4. Remove the O/D (4, 5, 6) clutch hub, No. 2 thrust bearing.
5. Remove the O/D (4, 5, 6) clutch snap ring.
6. Remove the O/D (4, 5, 6) clutch pressure plate and clutch assembly.
7. Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and
Forward/Intermediate Spring Compressor 307-584/2 on the balance piston.

8. Using a press, compress the O/D (4, 5, 6) clutch return spring and remove the snap ring.
9. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and
Forward/Intermediate Spring Compressor 307-584/2.
10. Remove and discard the balance piston.
11. Remove the O/D (4, 5, 6) piston return spring.
12. Install the clutch support tower in the transmission case and install the 3 bolts.

13. Remove the Input Shaft Support Seal Installer 307-578/1 (sizer).
14. Install the No. 1 O/D /direct clutch assembly thrust bearing.
15. Position the O/D /direct clutch assembly in the transaxle case.
16. Apply compressed air to the O/D (4, 5, 6) clutch piston port and remove the O/D (4, 5, 6) clutch
piston.

17. Remove the O/D /direct clutch assembly from the transaxle case.
18. Remove the O/D (4, 5, 6) clutch piston seal from the O/D /direct clutch assembly.
19. Remove the 2 seals from the O/D (4, 5, 6) clutch piston.
20. NOTICE: Only compress the direct clutch piston return spring far enough to take the tension
from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston
alignment tab may be broken off.
Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and
Forward/Intermediate Spring Compressor 307-584/2 on the direct (3, 5, R) clutch cylinder. Using a
press, compress the direct (3, 5, R) clutch piston return spring, and remove the snap ring.
1. Do not contact the O/D /direct clutch hub and shaft assembly with the direct (3, 5, R) clutch
cylinder.
2. Remove the snap ring.

22. Remove the direct (3, 5, R) clutch cylinder.
23. Remove and discard the direct (3, 5, R) clutch piston.
24. NOTE: Note the position of the return spring for assembly. The flat side faces down.
Remove the direct (3, 5, R) clutch piston return spring.

25. Remove the direct (3, 5, R) clutch snap ring.

1. Slightly lift up on the direct (3, 5, R) clutch so that the snap ring floats freely.
2. Using a suitable tool, compress the snap ring.
3. Allow the direct (3, 5, R) clutch and pressure plate to drop so that the snap ring is out of the
pressure plate groove.
4. Remove the snap ring.
26. Remove the direct (3, 5, R) clutch pressure plate, clutch pack and wave spring.
27. Remove and discard the 3 direct (3, 5, R) clutch piston seals.
Assembly
1. Clean and inspect the O/D /direct clutch assembly for damage or excessive wear and install new
components as necessary.
2. Install new direct (3, 5, R) clutch piston seals and lubricate the seals with petroleum jelly.

3. Install the direct (3, 5, R) clutch wave spring.
4. Soak the direct (3, 5, R) clutch pack in clean automatic transmission fluid.
5. Install the direct (3, 5, R) clutch assembly and pressure plate.
6. Install the direct (3, 5, R) clutch snap ring.

1. Using a suitable tool, compress the snap ring.
2. Lift the direct (3, 5, R) clutch so that the snap ring is in the groove of the pressure plate.
3. Release the tension on the snap ring.

7. NOTE: Install the direct (3, 5, R) clutch piston return spring with the flat side facing down.
Install the direct (3, 5, R) clutch piston return spring.
8. Lubricate a new direct (3, 5, R) clutch piston with petroleum jelly and install the piston.
9. Install the direct (3, 5, R) clutch cylinder.
10. NOTICE: Only compress the direct clutch piston return spring far enough to take the tension
from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston
alignment tab may be broken off.
Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and
Forward/Intermediate Spring Compressor 307-584/2 on the direct (3, 5, R) clutch cylinder. Using a
press, compress the direct (3, 5, R) clutch piston return spring, and install the snap ring.
1. Do not contact the O/D /direct clutch hub and shaft assembly with the direct (3, 5, R) clutch
cylinder.
2. Install the snap ring.

12. Install 2 new seals on the O/D (4, 5, 6) clutch piston and lubricate the seals with petroleum jelly.
13. Install a new O/D (4, 5, 6) clutch piston inner seal and lubricate the seal with petroleum jelly.
14. Position the O/D (4, 5, 6) clutch piston in place.

15. Using the Overdrive Clutch, Balance Piston, and Direct Clutch Compressor 307-589/1, install the O/D
(4, 5, 6) clutch piston into the O/D /direct clutch assembly by hand.
16. NOTE: Holes face up on the O/D (4, 5, 6) clutch piston return spring.
Install the O/D (4, 5, 6) clutch piston return spring.
17. Lubricate the seals on a new balance piston and position the piston in place.
18. Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and
Forward/Intermediate Spring Compressor 307-584/2 on the balance piston.
19. Using a press, compress the O/D (4, 5, 6) clutch return spring and install the snap ring.

21. Install the No. 2 thrust bearing.
22. Install the O/D (4, 5, 6) clutch hub.
23. Soak the O/D (4, 5, 6) clutch pack in clean automatic transmission fluid.
24. Install the O/D (4, 5, 6) clutch pack.

25. Install the O/D (4, 5, 6) clutch pressure plate.
26. Install the O/D (4, 5, 6) clutch snap ring.
27. Install the input shaft.
28. While holding the input shaft in place, install the snap ring.
29. Position the O/D /direct clutch assembly in the transaxle case, install Dial Indicator Gauge With
Holding Fixture 100-002 or a suitable dial indicator and position the plunger on the O/D (4, 5, 6)

clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the O/D (4, 5, 6) clutch piston port
while recording the clutch pack clearance on the Dial Indicator. The clearance should be between
0.950 mm (0.037 in) and 1.778 mm (0.07 in). If the clearance is out of range, check the O/D (4, 5, 6)
clutch pack for correct installation. If the O/D (4, 5, 6) clutch pack is correctly installed, install a new
O/D (4, 5, 6) clutch pack.
30. Position the plunger on one of the top direct (3, 5, R) clutch plate tabs. Apply 483 kPa (70 psi) of air
pressure to the direct (3, 5, R) clutch piston port while recording the clutch pack clearance on Dial
Indicator Gauge With Holding Fixture 100-002. The clearance should be between 0.412 mm (0.016
in) and 1.728 mm (0.068 in). If the clearance is out of range, check the direct (3, 5, R) clutch pack for
correct installation. If the direct (3, 5, R) clutch pack is correctly installed, install a new direct (3, 5,
R) clutch pack.
31. Remove Dial Indicator Gauge With Holding Fixture 100-002, O/D /direct clutch assembly and the
No. 1 O/D /direct clutch assembly thrust bearing.


SUBASSEMBLIES
Center Support
Special Tool(s)
Compressor, Center Support Piston Spring

307-630
Seal Protector, Low Reverse Piston

307-628 (includes 307-628/1 and
307-628/2)
Seal Protector, Low Reverse / 1-2-3-4
Piston
307-629
Disassembly
NOTICE: The piston return spring, snap ring or snap ring retainer from the low/reverse clutch side of
the center support are not interchangeable with the forward clutch side of the center support. When
disassembling the center support, be careful not to mix the components from the low/reverse clutch side
with the forward clutch side of the center support. Failure to assemble the center support with the
components in the correct side will result in damage to the center support, low/reverse or forward
clutch.
1. NOTE: The low/reverse clutch piston in the center support is the side of the center support with the
long legs.
Using the Center Support Piston Spring Compressor 307-630 and a press, compress the low/reverse
clutch return spring and remove the snap ring and the snap ring retainer.
2. Remove the low/reverse clutch return spring.
Center Support 4026

3. Apply 483 kPa (70 psi) of air pressure to the low/reverse clutch piston port and remove the
low/reverse clutch piston.
4. NOTE: The forward clutch piston in the center support is the side of the center support with the short
legs.
Using the Center Support Piston Spring Compressor 307-630 and a press, compress the forward (1, 2,
3, 4) clutch return spring and remove the snap ring and the snap ring retainer.
5. Remove the return spring from the forward (1, 2, 3, 4) clutch piston.
Center Support 4027

6. Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port and remove the
forward (1, 2, 3, 4) clutch piston.
Assembly
NOTICE: The piston return spring, snap ring or snap ring retainer from the low/reverse clutch side of
the center support are not interchangeable with the forward clutch side of the center support. When
assembling the center support, be careful not to mix the components from the low/reverse clutch side
with the forward clutch side of the center support. Failure to assemble the center support with the
components in the correct side will result in damage to the center support, low/reverse or forward
clutch.
1. Clean and inspect the center support for damage. Install a new center support if necessary.
2. NOTE: The forward clutch piston in the center support is the side of the center support with the short
legs.
Install the Low Reverse Piston Seal Protector 307-628/2 and the Low Reverse / 1-2-3-4 Piston Seal
Protector 307-629 on the forward clutch piston side of the center support.
3. Lubricate the sealing surfaces of the forward (1, 2, 3, 4) clutch piston with petroleum jelly.
Center Support 4028

4. Position the forward (1, 2, 3, 4) clutch piston on Low Reverse Piston Seal Protector 307-628/2 and the
Low Reverse / 1-2-3-4 Piston Seal Protector 307-629 and push it down into the center support.
5. Install the forward (1, 2, 3, 4) clutch piston return spring.
6. Using the Center Support Piston Spring Compressor 307-630 and a press, compress the forward (1, 2,
3, 4) clutch return spring and install the snap ring retainer and the snap ring.
7. Inspect the snap ring to be sure it is seated in the groove on the center support.
Center Support 4029

8. Turn the center support over and install the Low Reverse Piston Seal Protector 307-628/1 and
307-628/2 on the low/reverse piston side of the center support.
9. Lubricate the sealing surfaces of the low/reverse piston with petroleum jelly.
10. Position the low/reverse clutch piston on the Low Reverse Piston Seal Protector 307-628/1 and
307-628/2 and push it down into the center support.
11. Install the low/reverse piston return spring.
Center Support 4030

12. Using the Center Support Piston Spring Compressor 307-630 and a press, compress the low/reverse
clutch return spring and install the snap ring retainer and the snap ring.
13. Inspect the snap ring to be sure it is seated in the groove on the center support.
Center Support 4031

ASSEMBLY Procedure revision date: 06/03/2011
Transaxle
Special Tool(s)
Compressor, Forward Clutch Spring

307-574 (includes 307-574/1 and
307-574/2)
Compressor, Forward/Intermediate Spring
307-584 (includes 307-584/1 and
307-584/2)
100-002 (TOOL-4201-C)
Handle
205-153 (T80T-4000-W)
Handle, Torque Converter

307-091 (T81P-7902-C)
Holding Fixture
307-625

307-578 (includes 307-578/1, 307-578/2
and 307-578/3)
Installer, Bushing
307-664
Installer, Differential Seal

307-626
Installer, RH Halfshaft Fluid Seal

307-428
Manual Lever Seal Installer

307-581

307-566
Seal Protector, 2-6 Piston

307-632
Transaxle 4032
Seal Protector, Turbine Shaft

307-635
Shim Selection Gauge

307-300 (T94P-77000-Q) (17-055)
Spring Compressor, 2-6 Piston Return

307-633 (Includes 307-633/1 and
307-633/2)
Material
Item Specification
XT-10-QLVC
TA-29
Disassembled Views
Disassembled Views 4033


2 7A130 Clutch support tower
3 7D019 Clutch support tower seals (4 required)
4 W302855 Clutch support tower bolt (3 required)
5 7F242 No. 1 thrust bearing
6 7E005 Intermediate (2, 6) clutch piston
7 7B070 Intermediate (2, 6) clutch piston return spring
8 7D483 Intermediate (2, 6) clutch return spring snap ring
9 7E005 Intermediate (2, 6) clutch apply ring
10 7C122 Direct (3, 5, R) clutch cylinder snap ring
11 7F283 Direct (3, 5, R) clutch cylinder
12 7A262 Direct (3, 5, R) clutch piston
13 7F235 Direct (3, 5, R) clutch piston return spring
14 7C099 Direct (3, 5, R) clutch piston inner (rear) seal

15 7C099 Direct (3, 5, R) clutch piston inner (front) seal

16 7A548 Direct (3, 5, R) clutch piston outer seal
17 7C122 Input shaft snap ring
18 7G384 Direct (3, 5, R)/Overdrive (O/D) (4, 5, 6) clutch
cylinder and hub assembly
19 7A548 O/D (4, 5, 6) clutch piston inner seal
20 7F213 Input shaft
22 7B070 Direct (3, 5, R) clutch wave spring
23 7B164 Direct (3, 5, R) clutch friction plates (3 required)
24 7B442 Direct (3, 5, R) clutch steel plates (3 required)
25 7B066 Direct (3, 5, R) clutch pressure plate
26 7D483 Direct (3, 5, R) clutch snap ring
27 7A548 O/D (4, 5, 6) clutch piston outer (rear) seal
28 7A548 O/D (4, 5, 6) clutch piston outer (front) seal
29 7A262 O/D (4, 5, 6) clutch piston
30 7F222 O/D (4, 5, 6) clutch piston return spring
31 7H360 O/D (4, 5, 6) clutch balance piston
32 7C122 O/D (4, 5, 6) clutch piston snap ring
33 7B164 O/D (4, 5, 6) clutch friction plates (5 required)
34 7B442 O/D (4, 5, 6) clutch steel plates (5 required)
35 7B066 O/D (4, 5, 6) clutch pressure plate
36 7D483 O/D (4, 5, 6) clutch snap ring
37 7H351 O/D (4, 5, 6) clutch hub
40 7E085 Intermediate (2, 6) clutch wave spring
41 7B164 Intermediate (2, 6) clutch friction plates (2
required)
42 7B442 Intermediate (2, 6) clutch steel plates (2
required)
43 7A089 One-Way Clutch (OWC)
44 7D491 Rear planet carrier/center ring gear
47 7B066 Low/reverse clutch pressure plate
48 7B164 Low/reverse clutch friction plates (3 required)
49 7B442 Low/reverse clutch steel plates (3 required)
50 7E085 Low/reverse clutch wave spring
51 7C122 Low/reverse clutch piston snap ring
52 7H318 Low/reverse clutch piston snap ring retainer
53 7B070 Low/reverse clutch piston return spring
54 7D402 Low/reverse clutch piston

56 7A262 Forward (1, 2, 3, 4) clutch piston

57 7B070 Forward (1, 2, 3, 4) clutch piston return spring
58 7D041 Forward (1, 2, 3, 4) clutch piston snap ring
retainer
59 7H365 Forward (1, 2, 3, 4) clutch piston snap ring
60 7D491 Center planetary carrier/front ring gear
61 7D063 Center planetary sun gear
64 7D491 Front planetary carrier/rear ring gear
65 7A019 Front planetary sun gear and shell assembly
67 7B070 Forward (1, 2, 3, 4) clutch wave spring
68 7B164 Forward (1, 2, 3, 4) clutch friction plates (2
required)
69 7B442 Forward (1, 2, 3, 4) clutch steel plates (2
required)
70 7B066 Forward (1, 2, 3, 4) clutch pressure plate
71 7D483 Forward (1, 2, 3, 4) clutch snap ring
72 7978 Transmission fluid baffle
73 W500214 Transmission fluid baffle bolt (2 required)
74 7060 Park gear
76 7C122 Drive sprocket snap ring
79 7D234 No. 11 thrust washer
80 7048 Input shaft seal
81 7A098 Transmission fluid filter
82 7L027 Magnet
83 W302860 Pump-to-torque converter housing bolt (8
required)
85 7A248 Pump assembly-to-torque converter housing
O-ring seal
86 7A248 Torque converter hub seal
87 7P113 Torque converter hub seal retainer
88 7F343 Different ring gear
89 7C122 Differential ring gear snap ring
90 7H245 Differential transmission fluid baffle
91 W500214 Differential transmission fluid baffle bolt (2
required)
93 W701606 Torque converter housing stud bolt
94 7A443 Torque converter housing bolt (16 required)


96 1177 RH halfshaft seal
97 391308-S Transaxle filler tube O-ring
99 W520101 Transaxle filler tube nut
103 7F342 Differential sun gear
104 7F465 Differential assembly
106 7B362 Torque converter housing-to-transaxle case
guide pins
107 7D070 Park pawl spring
108 7A441 Park pawl
109 7D071 Park pawl pin
112 7H557 Transmission Range (TR) sensor
114 7G100 Manual control shaft pin
116 W708455 Manual control lever nut
117 7E332 Manual valve detent spring
118 W711235 Manual valve detent spring bolt
119 7J387 Lubrication funnel
120 7A248 Torque converter housing-to-transaxle case seal
(large)
121 7A248 Torque converter housing-to-transaxle case seal
(small) (4 required)
122 7B431 Main control alignment pin
123 7C207 Main control stud
124 7G199 Main control-to-center support seal (2 required)
125 7H322 Thermal bypass valve and sleeve
126 - Thermal bypass valve spring (part of 7H322)
127 W713644 Output Shaft Speed (OSS) sensor bolt
128 7H103 OSS sensor
131 N605770 Separator plate-to-soledoid body bolt (2
required)
132 7Z490 Main control valve body-to-solenoid body
separator plate

135 W302863 Main control-to-transaxle case bolt (long) (10

required)
required)
138 7G276 Main ctrol leadframe
142 W714629 Main control cover stud bolt (5 required)
143 W500214 Main control cover bolt (8 required)
144 7010 Drain plug
145 7H398 Line pressure tap
146 7D273 Transmission fluid cooler tube fittings (2
required)
148 7025 LH halfshaft bushing
149 7M101 Turbine Shaft Speed (TSS) sensor
150 W500214 TSS bolt
151 7A246 Vent tube
152 W500214 Lubrication funnel bolts
153 7G342 Solenoid body strategy tag
154 7B148 Transaxle service identification tag
155 - Direct clutch (3, 5, R)
156 - Intermediate clutch (2, 6)
157 - O/D clutch (4, 5, 6)
158 Forward clutch (1,
td>- 2, 3, 4)
159 - Low/reverse clutch
All vehicles
1. Clean and inspect the transaxle case for damage. Clean the silicone from the transaxle case-to-torque
converter housing sealing surface and the main control cover sealing surface.
2. Assemble the Handle 205-153 and the Bushing Installer 307-664 and install a new bushing on the
Bushing Installer.

3. Using the Handle 205-153 and the Bushing Installer 307-664, install the new bushing in the transaxle
case.
4. Assemble the Handle 205-153 and Seal Installer 307-626. Install a new LH halfshaft seal on the
Differential Seal Installer 307-626.
5. Using the Differential Seal Installer 307-626 and Handle 205-153, install the new LH halfshaft seal in
the transaxle case.
6. Install a new manual control shaft seal on Manual Lever Seal Installer 307-581.
7. Using the Manual Lever Seal Installer 307-581, install the new manual control shaft seal in the
transaxle case.

8. If not previously installed, install the clutch support tower and the 3 bolts.
9. Remove Input Shaft Support Seal Installer 307-578/1.
10. Install 2-6 Piston Seal Protector 307-632.
11. Lubricate the seals on the intermediate (2, 6) clutch piston with clean transmission fluid.
12. NOTICE: Be sure the bleed hole is aligned in the correct position as noted during disassembly
or damage to the transaxle can occur.
Install the intermediate (2, 6) clutch piston on the seal protector with the bleed hole aligned at the top
of the transaxle case.

13. Position the intermediate (2, 6) clutch piston return spring on the piston to align the piston before
pushing it in its bore. The tabs of the return spring should fit into the indentions of the piston and the 2
outer tabs should be at the clockwise most position of the open area at the bottom of the transaxle
case. The bleed hole on the piston should be aligned between the inner double tabs of the return
spring.
1. Outer tabs
2. Open area at the bottom of the transaxle case
3. Bleed hole
4. Inner double tabs
14. Remove the intermediate (2, 6) clutch piston return spring.
15. Install Forward/Intermediate Spring Compressor 307-584/1 on the intermediate (2, 6) clutch piston.
16. Using Forward/Intermediate Spring Compressor 307-584/1, push the intermediate (2, 6) clutch piston
into the clutch cylinder by hand.

17. Remove Forward/Intermediate Spring Compressor 307-584/1 and Clutch Piston Seal Protector
307-632.
18. NOTICE: Be sure the return spring is positioned correctly with the forward clutch bleed hole
aligned between the inner double tabs and the outer tab in the clockwise most position of the
slot at the bottom of the case or damage to the transaxle can occur.
Install the intermediate (2, 6) clutch piston return spring. The tabs of the return spring should fit into
the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the slot at
the bottom of the case. The bleed hole on the piston should be aligned between the inner double tabs
of the return spring.
1. Outer tabs
2. Bleed hole
3. Inner double tabs
19. NOTICE: Be sure the snap ring is aligned with the gap facing the front of the transaxle or
damage to the transaxle can occur. The front of the transaxle is where the low/reverse and
forward (1, 2, 3, 4) clutch hydraulic ports are located.
Position the snap ring in place. Align the gap of the snap ring to face the front of the transaxle.
1. Snap ring
2. Snap ring gap
3. Low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports (located at the front of the
transaxle case)
20. Install the 2-6 Piston Return Spring Compressor 307-633/2 on the transaxle case to center the
intermediate (2, 6) clutch return spring.

21. Install the 2-6 Piston Return Spring Compressor 307-633/1 on the snap ring.
22. Install Forward Clutch Spring Compressor 307-574/1 on the transaxle case.
23. NOTICE: Be sure the return spring is centered or it can bind on the snap ring groove and cause
damage to the transaxle case.
Using the Forward Clutch Spring Compressor 307-574/1 and the 2-6 Piston Return Spring
Compressor 307-633, install the intermediate (2, 6) clutch snap ring in the groove.
24. Remove the Forward Clutch Spring Compressor 307-574/1 and the 2-6 Piston Return Spring
Compressor 307-633.
25. Install the intermediate (2, 6) clutch apply ring. Tap the ring in place using a suitable tool.

26. NOTICE: Be sure to install the No. 1 thrust bearing with the flat side facing up or damage to the
transaxle can occur.
Install the No. 1 thrust bearing with the flat side facing up.
27. Install the overdrive/direct clutch assembly.
28. NOTICE: Be sure to install the No. 3 thrust bearing with the flat side facing down or damage to
the transaxle can occur.
Install the No. 3 thrust bearing with the flat side facing down.
29. Install the direct/intermediate clutch hub and rear sun gear assembly.

30. Install the intermediate (2, 6) wave spring assembly.
31. Soak the intermediate (2, 6) clutch assembly in clean transmission fluid.
32. Install the intermediate (2, 6) clutch assembly, temporarily reversing the top friction and steel plates
for the clutch stack-up measurement.
33. Install the Shim Selection Gauge 307-300 on the transaxle case.
34. Using a suitable depth gauge, measure and record as measurement A, the distance from the Shim
Selection Gauge 307-300 to the top of the intermediate (2, 6) clutch pack at 3 different points and
average the 3 distances.

35. Using a suitable depth gauge, measure and record as measurement B, the distance from the top of
Shim Selection Gauge 307-300 to the transaxle case step above the intermediate (2, 6) clutch.
36. Subtract measurement B from measurement A The clearance should be between 0.240 mm (0.009 in)
and 2.60 mm (0.102 in). If the clearance is out of range, check the intermediate (2, 6) clutch pack for
correct installation. If the intermediate (2, 6) clutch pack is correctly installed, install a new clutch
pack.
Description Reading
Measurement A
Measurement B
Subtract measurement B from measurement A and check to see if it is within range of
0.240 mm (0.009 in) and 2.60 mm (0.102 in)
37. NOTE: When the intermediate (2, 6) clutch is correctly installed, a friction plate is on top.
Remove the top intermediate (2, 6) clutch friction and steel plate and correctly install the plates back
in the transaxle case.

38. Install the One-Way Clutch (OWC) assembly.
39. Install the rear planetary carrier/center ring gear assembly.
40. NOTE: Note the position of the low/reverse pressure plate. When installing the center support, the
long support legs must fit through the low/reverse pressure plate and rest on the OWC .
Position the low/reverse pressure plate so that the center support legs fit through the pressure plate
and rest on the OWC and install the low/reverse pressure plate.
41. Soak the low/reverse clutch in clean automatic transmission fluid.
42. Align the low/reverse clutch pack with the pressure plate and install it in the transaxle case
temporarily reversing the wave spring and top steel plate.

43. Install the Shim Selection Gauge 307-300 on the side of the center support with the long support legs.
44. Using a suitable depth gauge, measure and record as measurement A, the distance from the top of
Shim Selection Gauge 307-300 to the contact surface of the low/reverse clutch piston.
45. Using a suitable depth gauge, measure and record as measurement B, the distance from the top of
Shim Selection Gauge 307-300 to the leg surface of the center support.
46. Subtract measurement B from measurement A and record as measurement C.
Description Reading
Measurement A
Measurement B
Subtract measurement B from measurement A and record as measurement C.

47. Install the Shim Selection Gauge 307-300 on the transaxle case.
48. Using a suitable depth micrometer, measure and record as measurement D, the distance from the
Shim Selection Gauge 307-300 to the top of the OWC .
49. Using a suitable depth gauge, measure and record as measurement E, the distance from the top of
Shim Selection Gauge 307-300 to the top of the low/reverse clutch at 3 different points and average
the 3 distances.
50. Subtract measurement E from measurement D and record as measurement F.
Description Reading
Measurement D
Measurement E
Subtract measurement E from measurement D and record as measurement F

51. Subtract measurement F from measurement C to get the low/reverse clutch clearance. The clearance
should be between 0.406 mm (0.015 in) and 2.000 mm (0.078 in). If the clearance is out of range,
check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly
installed, install a new clutch pack.
Description Reading
Measurement C
Measurement F
Subtract measurement F from measurement C and check to see if it is within range of 0.406
mm (0.015 in) and 2.000 mm (0.078 in)
52. NOTE: When the low/reverse clutch is correctly installed, the wave spring is on top.
Remove the top low/reverse clutch steel plate and wave spring and correctly install the plates back in
the transaxle case.
53. NOTE: Be sure the center support is installed with the long support legs facing down and the feed
holes facing the front of the transaxle.
Install the center support with the long legs facing down and the feed holes aligned with the feed
holes in the transaxle case.
1. Long center support legs face down

2. Feed holes face the front of the transaxle case
54. Install the No. 5 and No. 6 thrust bearings.


55. Install the center sun gear.
56. Install the center carrier/front ring gear assembly.
57. Install the No. 7 and No. 8 thrust bearings.

58. Install the front planetary/rear ring gear assembly.
59. Install the forward (1, 2, 3, 4) clutch wave spring.

60. Soak the forward (1, 2, 3, 4) clutch pack in clean automatic transmission fluid.
61. Install the forward (1, 2, 3, 4) clutch pack.
62. Install the forward (1, 2, 3, 4) clutch pressure plate.
63. NOTICE: Be sure to install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side
facing down or the snap ring can come loose, causing damage to the transaxle.
Install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side down with the gap facing the
front of the transaxle.
1. Forward (1, 2, 3, 4) clutch snap ring

2. Forward (1, 2, 3, 4) clutch snap ring gap
64. Using a suitable tool, seat the snap ring in the snap ring groove.

65. Install Dial Indicator Gauge With Holding Fixture 100-002 or a suitable dial indicator on the transaxle
case and position the plunger on the top forward (1, 2, 3, 4) clutch friction plate.
66. Install the new low/reverse and forward (1, 2, 3, 4) clutch feed seals in the transaxle case.
67. Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port while recording the
clutch pack clearance on the dial indicator. The clearance should be between 0.076 mm (0.002 in) and
1.840 mm (0.072 in). If the clearance is out of range, check the forward (1, 2, 3, 4) clutch pack for
correct installation and the transaxle for correct assembly. If the forward (1, 2, 3, 4) clutch pack is
correctly installed, install a new forward (1, 2, 3, 4) clutch pack.

68. Install the front planetary sun gear and shell assembly.
70. Install the park pawl.
71. Install the park pawl pin and spring.
72. Install the park pawl actuator rod in the Transmission Range (TR) sensor.
73. Position the park pawl aside and position the park pawl actuator rod and the TR sensor in the
transaxle case.

74. Install the manual control shaft and align the roll pin holes.
75. Install the manual control shaft roll pin.
76. NOTICE: Make sure to hold the manual control lever while tightening the manual control lever
77. Install the 5 new clutch feed seals.

78. Position the transmission fluid baffle in place and install the 2 bolts.
79. Position the lube funnel in place and install the 2 bolts.
81. Simultaneously install the drive/driven sprocket and chain assembly. Lightly tap on the driven
sprocket to be sure it is fully seated in the case.

83. Install the No. 13 thrust washer.
84. Install the final drive sun gear.

85. Install the differential assembly.
87. Install the Turbine Shaft Seal Protector 307-635 on the input shaft.
88. Clean the torque converter housing sealing surface.

89. Assemble the Handle 205-153 and Differential Seal Installer 307-626. Install a new RH seal on the
Seal Installer 307-626.
90. Using the Handle 205-153 and Differential Seal Installer 307-626, install the new RH halfshaft seal.
91. Install a new RH seal on the RH Halfshaft Fluid Seal Installer 307-428.
92. Using the RH Halfshaft Fluid Seal Installer 307-428, install the new RH halfshaft seal.
All vehicles
93. Install the differential ring gear in the torque converter housing.

94. NOTICE: Be sure the flat side of the beveled snap ring is facing down or the ring can come
loose, causing damage to the transaxle.
Install the beveled differential ring gear snap ring with the flat side facing down.
95. Seat the snap ring using a suitable tool.
96. Install the pump and filter assembly in the torque converter housing and install the 8 pump bolts.
97. Install the transmission fluid baffle and the 2 bolts.

98. NOTE: Be sure the sealing surfaces of the torque converter housing and the transaxle housing are
free of oil before applying silicone.
Apply silicone to the sealing surface of the transaxle case.

99. NOTE: Be sure the stud bolt is in the correct location as noted during disassembly.
Install the torque converter housing on the transaxle case and install the 17 transaxle case-to-torque
converter housing bolts.
1. Tighten to 24 Nm (18 lb-ft).

2. Stud bolt location.
100. Remove the Turbine Shaft Seal Protector 307-635.
101. Install the Turbine Shaft Speed (TSS) sensor and the bolt.
102. Install the Output Shaft Speed (OSS) sensor and the bolt.

103. Assemble the bypass valve in the sleeve and install the assembly in the case.
1. Bypass valve
2. Bypass valve sleeve
104. Install the bypass valve spring.
105. Install the new main control-to-transaxle case separator plate and align it on the stud and the guide
pin.
106. NOTE: Be sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
Position the main control assembly in place and align the manual valve on the TR sensor.

107. Install the nut hand-tight.
108. Install the short bolts hand-tight.
109. Install the long bolts hand-tight.
110. Tighten the main control bolts and the nut in a crisscross pattern.

111. Position the TR sensor detent spring in place with the alignment tab in the alignment hole and install
the bolt.
112. NOTE: Be sure the solenoid body-to-main control cover seal is installed with the holes facing up.
Install the solenoid body-to-main control cover seal.

118. NOTE: Install the main control cover stud bolts in the correct location as noted during disassembly.
Install the main control cover bolts.
1. Bolt location
2. Stud bolt location
119. NOTICE: The torque converter is heavy. Be careful not to drop it or damage will result.
Using the Torque Converter Handle 307-091, install the torque converter.
120. Remove the Torque Converter Handle 307-091.
121. Install the Torque Converter Retainer 307-566.

122. Remove the transaxle from the bench-mounted holding fixture.
123. Remove the Holding Fixture 307-625.

Transaxle - 2.5L
Special Tool(s)

300-OTC-1585AE

307-566
Support Bar, Engine

303-F072

Material
Item Specification
Motorcraft® MERCON® LV MERCON® LV
XT-10-QLVC
XG-4 and/or XL-5
TA-25
Installation
Transmission Fluid Cooler Backflushing and Cleaning in this section. Clean the transaxle-mounted
transmission fluid cooler tubes by hand.
1. Install the transmission fluid cooler tube bracket and the 2 nuts.
2. Tighten to 9 Nm (80 lb-in).

2. Install the transmission fluid cooler tubes in the transaxle by inserting the tube into the fitting until a
click is heard/felt. Pull back to confirm connection is secure and position them in the retainer mounted
on the main control cover studbolts.
3. Install the 2 secondary latches.
4. Position the transmission fluid cooler tubes in the retainers and close the 2 transmission fluid cooler
tube retainers.
6. Position the transmission fluid cooler tube in place and install the vent tube.
7. Install the transmission fluid filler tube nut.


8. Install the transmission fluid level indicator.
11. Position the transaxle into the engine compartment.
12. Remove the Torque Converter Retainer.
13. NOTE: Make sure that the dowel pins are installed in the engine block prior to installing the
transaxle.
Position the transaxle on the dowel pins.
14. NOTE: Note the location of the different length bolts.

Install the 4 front torque converter housing bolts.
15. Install the 3 rear torque converter housing bolts.

16. Remove the transmission jack.
17. Connect the transmission fluid cooler tubes by inserting the tube into the fitting until a click is
heard/felt. Pull back to confirm that the connection is secure.
18. Install the transmission fluid cooler tube secondary latches.
19. Connect the Turbine Shaft Speed (TSS) electrical connector.
20. Connect the transaxle main electrical connector.

21. NOTICE: Rotate the engine in a clockwise direction only or engine damage will occur.
Install 4 new torque converter nuts.
22. Install the rubber insulator in the bellhousing.
23. Install the starter motor. For additional information, refer to Section 303-06 .
nuts and the bolt.
25. Lift the transaxle until the transaxle support insulator bracket is aligned with the transaxle support
insulator, apply threadlock and sealant to the threads and install the through bolt.

27. Place the subframe assembly on the Powertrain Lift With Tilting Plate and raise the subframe into the
installed position.
Install the front subframe nuts.
Position the subframe brackets and install the bolts finger-tight.
Install the subframe nuts.

Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
Install the sway bar links and nuts to the struts.
33. Install the Electronic Power Assist Steering (EPAS) system wiring harness ground and the bolt behind
the RH splash shield.
34. Attach the EPAS system wiring harness pin-type retainer to the subframe under the LH fender splash
shield.

35. Attach the 2 EPAS system wiring harness pin-type retainers to the subframe.
36. Connect the 2 in-line EPAS system electrical connectors at the front of the subframe.
37. Install the LH halfshaft and the intermediate shaft. For additional information, refer to Section 205-04
.

42. Install the 2 roll restrictor bracket bolts.

43. If equipped, install the 7 screws and the underbody cover.
44. NOTICE: The steering gear/dash seal must be fully seated in the steering valve tower groove
before the retaining clips are fully engaged into the body. If the steering gear/dash seal is not
seated to the steering gear valve tower groove and the clips are not fully engaged to the body,
water and foreign material may enter the passenger compartment and damage the vehicle
interior can occur.
Install the steering gear/dash seal.
• Apply hand force to the center of the seal, install the steering gear/dash seal onto the steering
gear valve tower until the seal is fully seated in the valve tower groove. Install the steering
gear/dash seal until the retaining clips are fully engaged into the body.
45. Install the steering column shaft onto the steering gear and install a new bolt.

46. Install the steering joint cover and the 2 nuts.
47. Install the 3 top torque converter housing bolts.

48. Connect the wiring harness retainers to the main control cover studbolts.
49. Position the selector lever cable bracket in place and install the 2 nuts.

Section 307-05A .
52. Install the Air Cleaner (ACL) and the outlet pipe. For additional information, refer to Section
303-12A .
56. If a replacement transaxle assembly is being installed or a new solenoid body is installed, the PCM
will have to be reflashed with a new solenoid body strategy and identification data file. For additional
information, refer to Solenoid Body Strategy in this section.
57. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile


Transaxle - 3.0L
Special Tool(s)
Engine Lifting Bracket Set

303-1140

303-050 (T70P-6000)
Powertrain Lift
014-00765

307-566
Support Bar, Engine

303-F072
Material
Item Specification
XT-10-QLVC
XG-4 and/or XL-5
TA-25
Transmission Fluid Cooler Backflushing and Cleaning in this section.
All vehicles
1. Install the transmission fluid cooler tube bracket and the 2 nuts.

3. Install the 2 secondary latches.
tube retainers.
6. Position the transmission fluid filler tube in place and install the vent tube.

7. Install the transmission fluid filler tube nut.

8. Install the transmission fluid level indicator.
11. Position the transaxle into the engine compartment.
12. Remove the Torque Converter Retainer.

13. NOTE: Make sure that the dowel pins are installed in the engine block prior to installing the
transaxle.
Position the transaxle on the dowel pins of the engine.
14. Install the 2 back torque converter housing bolts.

15. Install the 2 bolts, 2 nuts and the stud in the front of the torque converter housing.
16. Remove the transmission jack.
heard/felt. Pull back to confirm connection is secure.

19. Connect the Turbine Shaft Speed (TSS) electrical connector.
20. Connect the transaxle main electrical connector.
21. Install 4 new torque converter nuts.

22. Install the inspection cover.
nuts and the bolt.
24. Lift the transaxle until the transaxle support insulator bracket is aligned with the transaxle support
insulator, apply threadlock and sealant to the threads and install the through bolt.

26. Remove the bolt and the Engine Lifting Bracket from the LH cylinder head.
27. Remove the upper half of the Engine Lifting Bracket Set.
28. Remove the lower half of the Engine Lifting Bracket Set.
29. Place the subframe assembly on the Powertrain Lift and raise the subframe into the installed position.


Install the stabilizer bar links and nuts to the struts.
36. Attach the 3 wiring harness retainers to the LH front of the subframe.
Install the 2 roll restrictor bracket bolts.

39. If equipped, install the heat shield and the 2 bolts.
40. Install the Power Transfer Unit (PTU). For additional information, refer to Section 308-07B .
41. Install the RH exhaust manifold heat shield on the manifold and install the 5 bolts.
42. Connect the RH Heated Oxygen Sensor (HO2S) electrical connector.
43. Install the intermediate shaft. For additional information, refer to Section 205-04 .
All vehicles

50. If equipped, install the 7 screws and the underbody cover.
interior can occur.

52. Install the steering intermediate shaft onto the steering gear and install a new bolt.
54. Install the EGR valve bracket and install the 2 bolts.
55. Install the EGR valve and tube. For additional information, refer to Section 303-08B .
56. Install the 3 upper torque converter housing bolts.


57. Connect the wiring harness retainer on the transmission fluid filler tube.
58. Connect the wiring harness retainers to the main control cover studbolts.
59. Position the selector lever cable bracket in place and install the 2 nuts.
Section 307-05A .
62. Install the Air Cleaner (ACL) and the outlet pipe. For additional information, refer to Section
303-12B .

66. If a replacement transaxle assembly is being installed or a new solenoid body is installed, the PCM
will have to be reflashed with a new solenoid body strategy and identification data file. For additional
information, refer to Solenoid Body Strategy in this section.

SECTION 307-01C: Automatic Transaxle/Transmission -

2012 Fusion, MKZ, Fusion Hybrid,
Electronically Controlled Continuously Variable Transmission
MKZ Hybrid Workshop Manual
(eCVT)
Procedure revision date:
SPECIFICATIONS
06/03/2011
Material
Item Specification
Fill
Capacity
Motorcraft® MERCON® LV MERCON® 4.05L
Automatic Transmission Fluid LV (4.28 qt) a b
XT-10-QLVC
a Transmission filled for life.
b The correct transaxle fill level is to the bottom of the fill plug, which is the upper plug.
Item Specification
Weight
Engine and transaxle assembly weight 257 kg (567 lb)
Transaxle weight 136 kg (300 lb)

Battery Junction Box (BJB) bolt 10 - 89
Battery Junction Box (BJB) nut 10 - 89
Drain plug 40 30 -
Fill plug 40 30 -
Manual control lever nut 12 - 106
Roll restrictor bolts 90 66 -
Transaxle support insulator nuts 90 66 -
Transmission Range (TR) sensor bolts 5 - 44
nbsp;



(eCVT)
DESCRIPTION AND OPERATION
06/03/2011
Transaxle Description
Transaxle Components
The Electronically Controlled Continuously Variable Transmission (eCVT) has the following internal
components:
• Traction motor
• Generator
• Planetary gearset
Range Selection
Park
With the range selector in PARK:
• the parking pawl locks the output shaft to the case.

• the ignition key can be removed.
• the ignition switch can be cycled from OFF to START or RUN. The ready indicator l will illuminate
on the Instrument Cluster (IC) when the ignition switch is cycled to the START postion.
The ready indicator light is located on the lower right hand corner of the IC .
Ready Indicator Light
Reverse
With the range selector in REVERSE:
• the vehicle may be operated in a rearward direction.
Transaxle Description 4094

• reversing lamps are illuminated.

• if the ready indicator light is not illuminated, which lights when the ignition switch is cycled to the
START position, there is no reverse gear engagement.
Neutral
With the range selector in NEUTRAL:
• no power flows through the transmission.

• the output shaft is disengaged from the drive wheels.
Drive
The range selector DRIVE position provides:
• low speed driving.

• acceleration.
• cruise conditions.
• deceleration.
• maximum fuel economy during normal operation.
If the ready indicator light is not illuminated, which lights when the ignition switch is cycled to the START
position, there is no forward gear engagement.
Low
The range selector LOW position provides:
• engine braking.
• improved traction on slippery roads.
Brake Shift Interlock System
The brake shift interlock system prevents a shift out of PARK unless the brake pedal is depressed. The brake
shift interlock system has a Brake Shift Interlock Actuator (BSIA) mounted on the floor selector lever
assembly. If the ignition switch is in the RUN position, the BSIA is continually on unless the brake pedal is
depressed.
External Controls
The external control of the eCVT is mechanically controlled by a selector lever cable connected to the floor
selector lever. The floor selector lever position determines PARK, REVERSE, NEUTRAL, DRIVE and low
modes.
Motor Electronics Cooling System (MECS)
The vehicle uses a pump driven cooling system, referred to as the Motor Electronics Cooling System (MECS)
pump, to transfer heat generated by the eCVT and the Hybrid Electric Vehicle (HEV) DC/DC converter to the
atmosphere. The system uses a coolant-to-air radiator design.
Ready Indicator Light 4095

The MECS pump is an electric pump that runs any time the ignition is in the ON position. Unlike traditional
cooling systems, there is no thermostat in the MECS , so coolant flow should be continuous and considerably
less than traditional powertrain cooling systems.
The flow direction is from the DC/DC converter to the MECS pump through the eCVT , then through the
MECS cooler from the LH to RH side of the vehicle back to the DC/DC converter.
The MECS cooling pump will make an audible noise if it is running and a slight vibration may be felt by
touch.
The MECS cooling system has a coolant expansion tank mounted on top of the transaxle.
Part
1 8C045 Motor Electronics Cooling System (MECS) coolant
expansion tank
2 8C351 MECS coolant expansion tank outlet hose
3 8B273 Electronically Controlled Continuously Variable
Transmission (eCVT)-to- MECS cooler hose
4 8005 MECS cooler
5 8B274 MECS cooler-to-DC/DC converter tube/hose assembly
6 14B227 DC/DC converter
7 15179 DC/DC converter-to- MECS pump hose
8 8C419 MECS pump
9 8A567 MECS pump-to- eCVT hose



(eCVT)
DIAGNOSIS AND TESTING
06/03/2011
Diagnostics
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Symptom Chart
Symptom Chart
elimination type of diagnostic approach to pinpoihe responsible system. If this is not the causal system for the
symptom, refer to Section 100-04 for the next likely system and continue diagnosis.
ConditionPossible SourcesAction
• Clunk - occurs when shifting from PARK to a DRIVE or REVERSE position
• Damaged transmission insulators
• INSPECT the transmission insulators for damage. INSTALL new insulators as necessary. REFER to
Transaxle Support Insulator or Transaxle Support Insulator - Anti-Roll in this section.
Diagnostics 4098

(eCVT)
GENERAL PROCEDURES
06/03/2011
Transmission Fluid Drain and Refill
Material
Item Specification
XT-10-QLVC
100-02 .
2. Turn the ignition to the OFF position.
3. Remove the 7 screws and the underbody cover.
4. NOTE: If an integral problem is suspected, drain the transmission fluid through a paper filter. A
small amount of metal particles may be found from normal wear. However, if excessive metal
particles are present, internal service will be required.
Remove the drain plug and drain the transmission fluid.
5. Remove the fill plug on the side of the transaxle.

6. NOTE: After the transmission fluid has been drained, clean the drain plug threads.
NOTE: Inspect the plug and washer for damage and install a new plug if necessary.
Install the drain plug.
7. NOTICE: Use only clean transmission fluid specific for this transmission. Do not use any
supplemental transmission fluid additives or cleaning agents. The use of these products can
cause internal transmission components to fail, which will affect the operation of the
transmission.
Fill the transaxle with clean transmission fluid as specified until the level reaches the bottom of the
fill plug hole.
8. NOTE: Clean the area around the fill plug removing transmission fluid that may have spilled on the
transaxle case.
Install the fill plug.
9. Install the underbody cover and 7 screws.


(eCVT)
IN-VEHICLE REPAIR
06/03/2011
Differential Seals - LH
Special Tool(s)
Handle
205-153 (T80T-4000-W)
Installer, Differential Seals RH and LH

307-665
Remover, Input Shaft Oil Seal

308-375
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
XT-10-QLVC
Removal
100-02 .
4. Remove the drain plug and drain the transmission fluid.
Differential Seals - LH 4101

5. Remove the LH halfshaft. For additional Information, refer to Section 205-04 .
6. Using the Slide Hammer and Input Shaft Oil Seal Remover, remove and discard the LH differential
seal.
Installation
1. Using the Differential Seal RH and LH Installer (two sided tool eCVT) and Handle, install the LH
differential seal.
3. NOTE: Inspect the plug and washer for damage and install a new plug if necessary.
Clean the drain plug threads and install the drain plug.

5. Fill the transaxle with clean transmission fluid as specified until the level reaches the bottom of the
fill plug hole.
transaxle case.
7. NOTE: The check and fill plug is located on the left side of the transaxle near the front.
NOTE: The transmission fluid is checked and filled by removing the fill plug and adding
transmission fluid to the bottom of the fill plug hole.
Start the engine and check for correct forward and reverse operation.



(eCVT)
IN-VEHICLE REPAIR
06/03/2011
Differential Seals - RH
Special Tool(s)
Handle, Driver 32 in
205-907
Installer, Differential Seals RH and LH

307-665
Remover, RH Halfshaft Fluid Seal

307-429
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
XT-10-QLVC
Removal
100-02 .
4. Remove the drain plug and drain the transmission fluid.
Differential Seals - RH 4105

6. Using the Slide Hammer and RH Halfshaft Fluid Seal Remover, remove and discard the RH
differential seal.
Installation
1. Using the Differential Seal RH and LH Installer (two sided tool eCVT) and Driver 32 Inch Handle,
install the RH differential seal.
3. NOTE: Inspect the plug and washer for damage and install a new plug if necessary.
Clean the drain plug threads and install the drain plug.

5. Fill the transaxle with clean transmission fluid as specified until the level reaches the bottom of the
fill plug hole.
transaxle case.
7. NOTE: The check and fill plug is located on the left side of the transaxle near the front.
NOTE: The transmission fluid is checked and filled by removing the fill plug and adding
transmission fluid to the bottom of the fill plug hole.
Start the engine and check for correct forward and reverse operation.



(eCVT)
IN-VEHICLE REPAIR
06/03/2011
Transmission Range (TR) Sensor
Removal
3. Disconnect the Transmission Range (TR) sensor electrical cotor.
4. Remove the nut and the manual lever.
5. Remove the 2 bolts, slide the TR sensor off of the manual shaft and remove the TR sensor.
Transmission Range (TR) Sensor 4109

Installation
1. Position TR sensor on the manual shaft, align the 2 TR sensor bolt holes and install the 2 bolts.
2. Install the manual control lever and the nut.

4. Adjust the selector lever cable. For additional information, refer to Section 307-05B . Connect the
selector lever cable end.



(eCVT)
IN-VEHICLE REPAIR
06/03/2011
Transaxle Support Insulator
Special Tool(s)
Support Bar, Engine

303-F072
Item Part Number < Description

1 W520214 Transaxle support insulator nuts
2 14A464 Transaxle support insulator
Removal and Installation
1. Remove the Air Cleaner (ACL) assembly. For additional information, refer to Section 303-12D .
2. Install the Engine Support Bar and support the engine and transaxle.
Transaxle Support Insulator 4112

3. Disconnect the hood ajar electrical connector.
4. Remove the bolt and the nut and position aside the Battery Junction Box (BJB).
5. Remove the 5 nuts and remove the transaxle support insulator and the bracket.
• To install, tighten to 90 Nm (66 lb-ft).
Transaxle Support Insulator 4113


(eCVT)
IN-VEHICLE REPAIR
06/03/2011
Transaxle Support Insulator - Anti-Roll

1 W706674 Rear roll restrictor bolt
2 W500545 Front roll restrictor bolt
3 6P082 Roll restrictor assembly
Removal
100-02 .
3. Remove the 2 bolts and remove the roll restrictor.
Installation
1. Position the roll restrictor in place and install the 2 bolts.



(eCVT)
REMOVAL
06/03/2011
Transaxle
1. NOTICE: Do not drain the oil when removing the engine to service the transaxle.
To remove the transaxle, follow the engine removal procedure. For additional information, refer to
Section 303-01D . Before removing the engine and transaxle from the vehicle, remove the drain plug
and drain the transmission fluid.
Transaxle 4116

(eCVT)
INSTALLATION
06/03/2011
Transaxle
1. To install the transaxle, follow the engine installation procedure. For additional information, refer to
Section 303-01D .
Transaxle 4117
SECTION 307-02A: Transaxle/Transmission Cooling - 2012 Fusion, MKZ, Fusion Hybrid, MKZ
Aisin AW21/6F35 Hybrid Workshop Manual
Material

Capacity
Motorcraft® MERCON® LV MERCON® LV 8.5L (9 qt) a
XT-10-QLV
Motorcraft® Premium Automatic WSS-M2C924-A 7.0L (7.4
Transmission Fluid qt) b
XT-8-QAW (US);
a 6F35 Transaxle
b Aisin AW21 Transaxle
Item Specification
Fluid
The use of any
transmission fluid
other than what is
recommended for
this transaxle will
cause transaxle
damage. Refer to
the material
specificatthe
correct fluid. The
transmission fluid
should be changed
every 96,560 km
(60,000 mi)
regardless of
normal or special
operating
conditions.
NOTICE: The
transmission
fluids used in the
6F35 and AW21
transaxles are
unique and are
not
interchangeable.
Transaxle 4118
NOTICE: Do not
use water-based
cleaners to clean
or flush the
transmission fluid
cooler tubes or
transmission
damage will
occur. Mineral
spirits can be used
to clean the
transmission fluid
cooler tubes,
providing the
transmission fluid
cooler tubes are
flushed with clean
automatic
transmission fluid
and blown dry
with shop air. Use
only clean
automatic
transmission fluid
designated for this
transaxle and
torque converter
being serviced.

Transmission fluid cooler tubes 10 - 89
Transmission fluid cooler tubes (at the radiator) 20 - 177
Transmission fluid fill plug (Aisin AW21) 39 29 -
Transaxle 4119
Transaxle 4120
Transaxle Cooling - Aisin AW21
These vehicles are equipped with an internal transmission fluid cooler. The transmission fluid cooler is
mounted in the engine radiator tank. During operation, transmission fluid travels from the transaxle to the
transmission fluid cooler, then back to the transaxle. The transmission fluid cooler transfers heat from the
transmission fluid to the engine coolant.

1 8005 Radiator
2 7H420 Transmission fluid e assembly
3 19710-A Transmission mounted fluid cooler tube
Transaxle Cooling - Aisin AW21 4121


These vehicles are equipped with an internal transmission fluid cooler. The transmission fluid cooler is
mounted in the engine radiator tank. During operation, transmission fluid travels from the transaxle to the
transmission fluid cooler, then back to the transaxle. The transmission fluid cooler transfers heat from the
transmission fluid to the engine coolant.
Transaxle Cooling
Part
1 8005 Radiator
2 7R081 Transmission fluid cooler supply tube assemblyes
transmission fluid to the transmission fluid cooler from
the transaxle)
3 7R081 Transmission fluid cooler return tube assembly
(transmission fluid return tube from the transmission fluid
cooler to the transaxle)
4 7J081 Transmission fluid cooler tube secondary latches
5 7H420 Transaxle mounted transmission fluid cooler tubes

Transaxle Cooling 4124

Special Tool(s)

Material
Item Specification
Transmission Fluid
XT-8-QAW (US); CXT-8-LAW12
(Canada)
Inspection and Verification
1. Verify mer concern by operating the vehicle to duplicate the condition.
2. If the inspection reveals an obvious concern(s) that can be readily identified, repair as necessary.
3. Install new components if a transmission fluid leak is found in any of the transaxle cooling
components.
4. If the concern(s) remains after the inspection, determine the symptom(s). GO to Symptom Chart -
Transaxle Cooling or GO to Symptom Chart - NVH .
Symptom Chart - Transaxle Cooling
Symptom Chart - NVH
Symptom Chart - NVH


• Vibration - a high frequency (20-80 Hz) that is felt through the seat or selector lever. Changes with
engine speed
• Transmission fluid cooler tubes grounded
• CHECK the transmission fluid cooler tubes. REPAIR as necessary.
Check Transmission Fluid Level and Condition
NOTICE: The vehicle should not be driven if the transmission fluid level indicator shows the
transmission fluid below the minimum fluid level mark or internal failure may result.
If the vehicle has been operated for an extended period of time at highway speeds, in city traffic, in hot
operating and ambient temperatures. The correct reading should be within the normal operating temperature
range.
Transmission Fluid Level Check
NOTE: The transmission fluid should be checked at normal operating temperature 60°C-70°C (140°F-158°F)
on a level surface. Normal operating temperature can be reached after approximately 32 km (20 mi) of driving
and can be checked using the scan tool.
Under normal circumstances the transmission fluid level should be checked during normal maintenance. If the
transaxle starts to slip, shifts slowly or shows signs of transmission fluid leaking, the transmission fluid level
should be checked.
1. With the transaxle in PARK, the engine at idle, foot pressed on the brake, move the selector lever
through each gear and allow engagement of each gear. Place the selector lever in the PARK position.
4. Install the transmission fluid level indicator back in the fluid indicator tube until it is fully seated, then
remove the indicator. The transmission fluid level should be within the normal operating range.
Part
1 - Transmission fluid level at operating temperature
60°C-70°C (140°F-158°F)

2 - Transmission fluid level cool 15°C-25°C (59°F-77°F)

3 - Do not drive mark
High Transmission Fluid Level
A transmission fluid level that is too high may cause the transmission fluid to become aerated due to the
churning action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of
transmission fluid from the vent tube and possible transaxle malfunction and/or damage. If an overfill reading
is indicated, refer to Section 307-01A .
A low transmission fluid level could result in poor transaxle engagement, slipping, malfunction and/or
damage. This could also indicate a leak in one of the transaxle seals or gaskets.
NOTICE: The use of any fluid other than what is recommended for this transaxle will cause transaxle
damage.
indicator tube. Do not overfill the transaxle. For transmission fluid type, refer to the specification chart in this
section.
2. Observe the color and the odor. The color under normal circumstances should be a dark red color, not
brown or black or have a burnt odor.
4. If evidence of solid material is found, the transmission fluid pan should be removed for further
inspection.
5. If the stain is a foamy pink color, this may indicate coolant in the transaxle. The engine cooling
system should also be inspected at this time.
6. If transmission fluid contamination or transaxle failure is confirmed by the sediment in the bottom of
the fluid pan, install a new transaxle. If installing a new transaxle, the transmission fluid cooler and
transmission fluid cooler tubes should be cleaned.
7. If the transaxle is to be overhauled or if installing a new transaxle, the fluid cooler must be
backflushed. Refer to Section 307-01A .


Special Tool(s)

Material
Item Specification
XT-10-QLV
1. Verify the customer concern by operating tto duplicate the condition.
2. If the inspection reveals obvious concern(s) that can be readily identified, repair as necessary.
3. Install new components if a transmission fluid leak is found in any of the transaxle cooling
components.
4. If the concern(s) remains after the inspection, determine the symptom(s). GO to Symptom Chart -
Transaxle Cooling or GO to Symptom Chart - NVH .
Symptom Chart - NVH
Symptom Chart - NVH


• Vibration - a high frequency (20-80 Hz) that is felt through the seat or selector lever. Changes with
engine speed
• Transmission fluid cooler tubes grounded
• CHECK the transmission fluid cooler tubes. REPAIR as necessary.
Check Transmission Fluid Level and Condition (All Vehicles)
NOTICE: The vehicle should not be driven if the transmission fluid level indicator shows the
transmission fluid below the minimum transmission fluid level mark or internal failure could result.
If the vehicle has been operated for an extended period of time, at highway speeds, in city traffic, in hot
operating and ambient temperatures. The correct reading should be within the normal operating temperature
range.
Transmission Fluid Level Check
NOTE: The transmission fluid should be checked at normal operating temperature 85°C-93°C (185°F-200°F)
on a level surface. Normal operating temperature can be reached after approximately 32 km (20 mi) of driving
and can be checked using the scan tool.
Under normal circumstances the transmission fluid level should be checked during normal maintenance. If the
transaxle starts to slip, shifts slowly or shows signs of transmission fluid leaking, the transmission fluid level
should be checked.
1. With the transaxle in PARK, gine at idle, foot pressed on the brake, move the selector lever through
each gear and allow engagement of each gear. Place the selector lever in the PARK position.
4. Install the transmission fluid level indicator back in the transmission fluid filler tube until it is fully
seated, then remove the indicator. The transmission fluid level should be within the crosshatch.
Item Description
1 Correct transmission fluid level at operating temperature 85°C-93°C (185°F-200°F)
2 Minimum transmission fluid level mark
3 Maximum transmission fluid level mark

4 Flat tow transmission fluid level
High Transmission Fluid Levelb>
A transmission fluid level that is too high may cause the transmission fluid to become aerated due to the
churning action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of
transmission fluid from the vent tube and possible transaxle malfunction and/or damage. If an overfill reading
is indicated, refer to Section 307-01B .
A low transmission fluid level could result in poor transaxle engagement, slipping, malfunction and/or
damage. This could also indicate a leak in one of the transaxle seals or gaskets.
NOTICE: Automatic transmission fluids are not interchangeable. The use of any fluid other than what
is recommended for this transaxle will cause transaxle damage.
transmission fluid level indicator tube with the selector lever in PARK and the engine idling. Do not overfill
the transmission fluid. For transmission fluid type, refer to the material chart in this section.
Flat Tow Fluid Level
Recreational flat towing of the vehicle may require the transmission fluid to be set to a lower fluid level. This
will prevent damage to the transmission. The transmission fluid level is within the normal operating range and
will not require the transmission fluid level to be readjusted after recreational towing.
2. Observe the color and the odor. The color under normal circumstances should be a dark red color, not
brown or black or have a burnt odor.
4. If evidence of solid material is found, the transmission fluid pan should be removed for further
inspection.
5. If transmission fluid contamination or transaxle failure is confirmed by the sediment in the bottom of
the transmission fluid pan, repair the transaxle and clean the transmission fluid cooler tubes and the
transmission fluid cooler.
6. If the transaxle is to be overhauled or if installing a new transaxle, the transmission fluid cooler must
be backflushed. Refer to Section 307-01B .


REMOVAL AND INSTALLATION Procedure revision date: 06/03/2011
Transmission Fluid Cooler
1. NOTE: The transmission fluid cooler is mounted in the radiator tank and cannot be serviced
separately.
Install a new radiator. For additional information, refer to Section 303-03A .
Transmission Fluid Cooler 4133

Transmission Fluid Cooler Tubes - Aisin AW21
Material
Item Specification
Transmission Fluid
(Canada)
Transmission Fluid Cooler Tubes - Aisin AW21

1 M52923 Transmission fluid cooler tube radiator fittings
2
3 7H420 Transmission fluid cooler tube assembly
4 19710-A Transmission fluid cooler tube fittings at the transaxle
5 256844 Transmission fluid cooler tube retaining clips
6 256679 Transmission fluid cooler tube retaining clip
Removal
Transmission Fluid Cooler Tubes - Aisin AW21 4134

100-02 .
2. Disconnect the upper transmission fluid cooler tube from the radiator.
3. Remove the bolts and the splash shield.
4. Remove the front splash shield.

1. Remove the 2 screws.
2. Remove the 4 retainers.
3. Remove the 4 bolts and the splash shield.
5. Disconnect the lower transmission fluid cooler tube from the radiator.
6. NOTICE: Use care not to overstretch or extend the hose clamps as damage may occur to the
hose clamp and cause a leak.

NOTICE: The hose clamps are held on the hose with a special epoxy. Damage may occur to the
hose if the clamp is removed from the hose. If the clamp or hose is damaged, install a new fluid
cooler tube.
Disconnect the transmission fluid cooler hoses from the transmission fluid cooler tubes.
7. Remove the 2 bolts and remove the transmission fluid cooler tubes.
8. NOTE: When removing the transmission fluid cooler tubes from the retainers, do not remove the
retainers from the shroud.
Remove the transmission fluid cooler tubes from the retainers.
9. Remove the transmission fluid cooler tube retainer and remove the transmission fluid cooler tubes.
Installation
1. Install new O-rings on the transmission fluid cooler tubes.

2. Install the transmission fluid cooler tubes.

3. Position the transmission fluid cooler tubes in place and install the retainer.
4. Install the transmission fluid cooler tubes in the retainers.
5. NOTE: The power steering hose is routed between the 2 transmission fluid cooler hoses.
Position the transmission fluid cooler hoses in place.
6. NOTICE: Use care not to overstretch or extend the hose clamps as damage may occur to the
hose clamp and cause a leak.
NOTICE: The hose clamps are held on the hose with a special epoxy. Damage may occur to the
hose if the clamp is removed from the hose. If the clamp or hose is damaged, install a new fluid
cooler tube.

Connect the transmission fluid cooler hoses to the transmission fluid cooler tubes.
7. Install the lower transmission fluid cooler tube in the radiator.

8. Install the front splash shield.

1. Position the splash shield in place and install the 2 screws.
2. Install the 4 retainers.
3. Install the 4 bolts.
9. Install the bolts and the splash shield.
10. Install the upper transmission fluid cooler tube in the radiator.

11. Remove the transmission fluid fill plug.
12. NOTE: Transmission fluid level at normal operating temperature is between the top 2 marks on the
fluid level indicator.
Check the transmission fluid level and add transmission fluid as necessary.
13. Install the transmission fluid fill plug.



Transmission Fluid Cooler Tubes - 6F35
Special Tool(s)

307-569
Material
Item Specification
XT-10-QLV
Transmission Fluid Cooler Tubes

1 - Transmission fluid cooler tube nut (part of 7H420)
2 7B407 Radiator splash shield
3 - Transmission fluid cooler tube nut (part of 7H420)
4 7J081 Transmission fluid cooler tube secondary latches
5 7R081 Transmission fluid cooler supply tube
6 7R081 Transmission fluid cooler return tube
Transmission Fluid Cooler Tubes - 6F35 4141

7 256844 Transmission fluid cooler tube retaining clips

8 256679 Transmission fluid cooler tube retaining clip
9 - Transmission fluid cooler tube retainer (part of 7H420)
10 - Transmission fluid cooler tube retainer (part of 7H420)
11 7H420 Transaxle mounted transmission fluid cooler return
tube
12 7H420 Transaxle mounted transmission fluid cooler supply
tube
Removal
NOTICE: Automatic transmission fluids are not interchangeable. The use of any fluid other than what
is recommended for this transaxle will cause transaxle damage.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
2. Disconnect the upper transmission fluid cooler tube from the radiator.
4. Remove the radiator splash shield.

5. Disconnect the lower transmission fluid cooler tube from the radiator.
Transmission Fluid Cooler Tubes 4142

8. NOTE: When removing the transmission fluid cooler tubes from the retainers, do not remove the
retainers from the shroud.
Release the transmission fluid cooler tube retainers and remove the transmission fluid cooler tubes
from the retainers.
9. Remove the transmission fluid cooler tube retainer and remove the transmission fluid cooler tubes
from the vehicle.
303-12A or Section 303-12B .

13. Remove the 2 transmission fluid cooler tube secondary latches.
Installation
2. Install the 2 transmission fluid cooler tube secondary latches.

tube retainers.
5. Install the ACL and the outlet pipe. For additional information, refer to Section 303-12A or Section
303-12B .
6. Position the transmission fluid cooler tubes in place in the vehicle and install the retainer.
7. Position the transmission fluid cooler tubes in the retainers and close the retainers.
heard/felt. Pull back to confirm that the connection is secure.

10. Install the lower transmission fluid cooler tube in the radiator.
11. Install the radiator splash shield

1. Install the 6 screws.
2. Install the 4 retainers.
12. If equipped, install the bolts and the splash shield.
13. Install the upper transmission fluid cooler tube in the radiator.

bsp;

SECTION 307-02B: Transaxle/Transmission Cooling - 2012 Fusion, MKZ, Fusion Hybrid, MKZ
Hybrid Hybrid Workshop Manual
Material
Item Specification Fill Capacity

Motorcraft® Specialty WSS-M97B55-A 2.75L (2.9 qt)
Green Engine Coolant approximate dry fill
VC-10-A2 (US); capacity a b
CVC-10-A (Canada)
Motorcraft® Specialty WSS-M97B44-D 2.75L (2.9 qt)
Orange Engine approximate dry fill
Coolant capacity a
VC-3-B (US);
CVC-3-B (Canada)
a Vehicles (built on or after July 6, 2009 through June 5, 2011) cooling systems are filled with Motorcraft®
Specialty Green Engine Coolant. Vehicles (built on or after June 6, 2011) are filled with Motorcraft®
Specialty Orange Engine Coolant. Mixing coolant types degrades the corrosion protection of the coolant. Do
not mix coolant types. Failure to follow these instructions may result in engine or cooling system damage.
b Genuine Mazda® Extended Life Coolant and Motorcraft® Specialty Green Engine Coolant are very
sensitive to light. Do NOT allow these products to be exposed to ANY LIGHT for a day or two. Extended
light exposure causes these products to degrade.
Description Nm lb-in
Motor Electronics Cooling System (MECS) bleed screw 3 27
MECS cooler hose bolt 15 133
MECS coolant expansion tank bolt 8 71
MECS coolant expansion tank nut 8 71
MECS radiator bolts 8 71


Transaxle Cooling
Motor Electronics Cooling System (MECS)
The vehicle uses a pump driven cooling system, referred to as the Motor Electronics Cooling System (MECS)
pump, to transfer heat generated by the Electronically Controlled Continuously Variable Transmission
(eCVT) and the Hybrid Electric Vehicle (HEV) DC/DC converter to the atmosphere. The system uses a
coolant-to-air radiator design.
The MECS pump is an electric pump that runs any time the ignition is in the ON position. Unlike traditional
cooling systems, there is no thermostat in the MECS , so coolant flow should be continuous and considerably
less than traditional powertrain cooling systems.
The flow direction is from the DC/DC converter to the MECS pump through the eCVT , then through the
MECS cooler from the LH to RH side of the vehicle back to the DC/DC converter.
The MECS cooling pump will make an audible noise if it is running and a slight vibration may be felt by
touch.
The MECS cooling system has a coolant expansion tank mounted on top of the transaxle.
Part
1 8C045 Motor Electronics Cooling System (MECS) coolant
expansion tank
3 8B273 Electronically Controlled Continuously Variable
Transmission (eCVT)-to- MECS cooler hose
4 8005 MECS radiator
5 8B274 MECS cooler-to-DC/DC converter tube/hose assembly
6 14B227 DC/DC converter
7 15179 DC/DC converter-to- MECS pump hose
8 8C419 MECS pump

9 8A567 MECS pump-to- eCVT hose

10 W710743 MECS bleed screw

Transaxle Cooling
Special Tool(s)
Flex Probe Kit

105-R025D


1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart
Mechanical Electrical
• Motor Electronics Cooling System (MECS) component • Battery Junction Box (BJB) fuse 13
damage: (15A)
♦ Motor electronics radiator • BJB fuse 47 (10A)
♦ MECS coolant hoses • MECS cooling pump relay ( BJB
♦ MECS coolant pump relay 44)
• Coolant leaks • Wiring harness
• Connector
• Circuitry
Symptom Chart - NVH
Symptom Chart - NVH


• Vibration - a high frequency (20-80 Hz) that is felt through the seat or selector lever
• Motor Electronics Cooling System (MECS) pump
• CHECK the MECS pump. INSTALL a new pump as necessary.
Pinpoint Tests
Pint Test A: MECS Cooling Pump Fault
Refer to Wiring Diagrams Cell 54 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Climate Control for
schematic and connector information.
Normal Operation
The Motor Electronics Cooling System (MECS) pump is electrically driven and controlled by the PCM
through the MECS pump relay. The PCM energizes the MECS pump relay by pulling the MECS pump output
to ground when the ignition is in the ON position.
This pinpoint test is intended to diagnose the following:

• Battery Junction Box (BJB) fuse 13 (15A)
• BJB fuse 47 (10A)
• MECS coolant pump
• Wiring
• MECS coolant pump relay
PINPOINT TEST A: MECS COOLING PUMP FAULT
NOTICE: Use the Flex Probe Kit for all test connections to prevent damage to the wiring terminals. Do
not use standard multi-meter probes.

A1 CHECK FOR DTCs
Yes
• Connect the scan tool. REFER to Section 307-01C .
• Enter the following diagnostic mode on the scan
tool: RETRIEVE. No
• Carry out the PCM on-demand self test. GO to A2 .
• Are DTCs retrieved?
A2 CHECK BJB FUSE 13 (15A)
Yes
• Check fuse: BJB 13 (15A). GO to A5 .
Normal Operation 4153

No
GO to A3 .
A3 CHECK THE MECS COOLANT PUMP
RELAY POWER SUPPLY CIRCUIT FOR A
SHORT TO GROUND
Yes
• Disconnect: BJB Fuse 13 (15A). GO to A4 .
• Disconnect: BJB Relay 44.
• Disconnect: BJB Relay 42. No
• Measure the resistance between the output side of REPAIR circuit SBB13 (GY/RD) for a short
BJB fuse 13 (15A) and ground. to ground. CONNECT all components. TEST

A4 CHECK THE MECS COOLANT PUMP AND
HEATER PUMP POWER SUPPLY CIRCUITS FOR
A SHORT TO GROUND
Yes
• Disconnect: MECS Coolant Pump C1466. The condition that caused BJB fuse 13 (15A)
• Disconnect: Heater Pump Motor C1450. to blow is not present. Inspect the wiring
• Measure the resistance between BJB relay 44 pin harness for an intermittent condition. Repeat
5 circuit CE621 (YE/GY), BJB side and ground. test Steps A3 and A4 while wiggling the
vehicle wiring harness and visually checking
for damage.
No
REPAIR circuit CE621 (YE/GY) or CHC01
(BN/YE) for a short to ground. CONNECT all
components. TEST the system for normal
operation.
• Measure the resistance between BJB relay 42 pin

5 circuit CHC01 (BN/YE), BJB side and ground.
• Are the resistances greater than 10,000 ohms?

RELAY ( BJB RELAY 44)
PINPOINT TEST A: MECS COOLING PUMP FAULT 4154

• Carry out the relay component test. Yes

GO to A6 .
Refer to Wiring Diagrams Cell 149 (
Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ) for No
component testing. INSTALL a new MECS pump relay ( BJB
• Is MECS pump relay ( BJB relay 44) OK? relay 44). TEST the system for normal
operation.
RELAY POWER SUPPLY CIRCUIT FOR AN
OPEN
Yes
• Measure the resistance between BJB fuse 13 GO to A7 .
(15A) circuit CE621 (YE/GY), BJB side and BJB
relay 44 pin 5 circuit CE621 (YE/GY), BJB side. No
REPAIR circuit CE621 (YE/GY) for an open.
CONNECT all components. TEST the system
for normal operation.

POWER SUPPLY CIRCUIT FOR AN OPEN
Yes
• Measure the resistance between BJB relay 44 pin GO to A8 .
5 circuit CE621 (YE/GY), BJB side and MECS
coolant pump C1466-2, circuit CE621 (YE/GY). No
REPAIR circuit CE621 (YE/GY) for an open.

GROUND CIRCUIT FOR AN OPEN
Yes
• Measure the resistance between MECS coolant GO to A9 .
pump 1466-1 circuit GD121 (BK/YE) and
ground. No
REPAIR circuit GD121 (BK/YE).


A9 CHECK BJB FUSE 47 (10A)
Yes
• Check fuse: BJB 47 (10A). GO to A10 .
No
REPAIR circuit CBK03 (GY) for a short to
ground. CONNECT all components. TEST
A10 CHECK FOR VOLTAGE SUPPLIED TO BJB
FUSE 47 (10A)
Yes
• Disconnect: BJB Fuse 47 (10A). GO to A11 .
• Ignition ON.
• Measure the voltage at the supply side of BJB No
fuse 47 (10A). REPAIR circuit CE612 (GY/VT) for an open.

RELAY CONTROL POWER SUPPLY CIRCUIT
FOR AN OPEN
Yes
• Ignition OFF. GO to A12 .
• Measure the resistance between the output side of
BJB fuse 47 (10A), circuit CBK03 (GY) and BJB No
relay 44 pin 1 circuit CBK03 (GY). REPAIR circuit CBK03 (GY) for an open.

A12 CHECK FOR GROUND AT THE MECS

COOLANT PUMP RELAY
Yes
• Connect: BJB fuse 47 (10A). INSTALL a new MECS pump. REFER to
• Ignition ON. Motor Electronics Pump in this section.
• Measure the voltage between BJB relay 44 pins 1 CONNECT all components. TEST the system
and 2, BJB side. for normal operation.
No
GO to A13 .

RELAY CONTROL GROUND CIRCUIT FOR AN
OPEN
Yes
• Ignition OFF. INSTALL a new PCM. REFER to Section
• Disconnect: PCM C175T. 303-14D . CONNECT all components. TEST
• Measure the resistance between BJB relay 44 pin the system for normal operation.
2, BJB side circuit CE318 (VT) and PCM
C175T-49 circuit CE318 (VT). No
REPAIR circuit CE318 (VT) for an open.


Motor Electronics Cooling System Draining and Filling
Material
Item Specification
Motorcraft® Specialty Green WSS-M97B55-A
Engine Coolant
VC-10-A2 (US); CVC-10-A
(Canada)
Motorcraft® Specialty Orange WSS-M97B44-D
Engine Coolant
VC-3-B (US); CVC-3-B (Canada)
Draining
NOTICE: The coolant must be recovered in a suitable, clean container for reuse or damage can occur to
the transaxle cooling system. If the coolant is contaminated, it must be recycled or disposed of correctly.
NOTICE: Always refill the Motor Electronics Cooling System (MECS) with the same type of coolant
that was drained from the system. Do not mix coolant types. Mixing coolant types may cause MECS
damage.
1. he vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .
4. Compress the constant tension clamps and remove the hoses from the transaxle to allow the coolant to
drain.
5. Connect the hoses to the transaxle and install the hose clamps.
Motor Electronics Cooling System Draining and Filling 4159

Filling and Bleeding
NOTICE: Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion
protection to the engine and cooling components. In order to obtain these protections, the engine
coolant must be maintained at the correct concentration and fluid level in the degas bottle. When
adding engine coolant, use a 50/50 mixture of engine coolant and distilled water.
To maintain the integrity of the coolant and the cooling system:
• Vehicle cooling systems are filled with Motorcraft® Specialty Green Engine Coolant or Motorcraft®
Specialty Orange Engine Coolant. Always fill the cooling system with the same coolant that is present
in the system. Do not mix coolant types.
• Do not add alcohol, methanol or brine, or any engine coolants mixed with alcohol or methanol
antifreeze. These can cause engine damage from overheating or freezing.
• Ford Motor Company does NOT recommend the use of recycled engine coolant since a
Ford-approved recycling process is not yet available.
• Used engine coolant should be disposed of in an appropriate manner. Follow community regulations
and standards for recycling and disposing of automotive fluids.
1. NOTICE: Adhesives, stop-leak pellets or small foreign material in the Motor Electronics
Cooling System (MECS) can cause poor performance or temporary blockage of the motor
electronics pump. Only use clean, approved coolant when filling the system.
Loosen the Motor Electronics Cooling System (MECS) bleed screw on the DC/DC converter and
slowly fill the coolant expansion tank with coolant until it begins to flow out of the bleed hole. Then,
close the bleed screw.
2. Turn the ignition to the ON position to actuate the MECS coolant pump and continue to fill the
coolant expansion tank to the FULL COLD level labeled on the side of the tank.
3. To bleed air from the MECS , turn the ignition switch to the OFF position. Loosen the MECS bleed
screw on the DC/DC converter and allow air to escape the MECS .


Motor Electronics Coolant Expansion Tank
Part
1 W505424 Motor Electronics Cooling System (MECS) coolant
expansion tank bolt
2 W701152 MECS coolant expansion tank nut
3 W701152 MECS coolant expansion tank
1. Drain the Motor Electronics Cooling System (MECS). For additional information, refer to Motor
Electronics Cooling System Draining and Filling in this section.
2. Remove the nut and the bolt and position the MECS coolant expansion tank aside.
3. Compress the constant tension clamp and remove the MECS hose from the coolant expansion tank.
Motor Electronics Coolant Expansion Tank 4162

Motor Electronics Coolant Expansion Tank 4163

Motor Electronics Cooler

1 8B273 Motor Electronics Cooling System (MECS)
radiator inlet hose
2 N808349 MECS radiator outlet tube bolt
3 8B274 MECS radiator outlet ho
4 W711685-S MECS radiator bolts
5 8005 MECS radiator
2. Remove the 4 bolts and the 2 retainers and position the front grille aside far enough to gain access to
the MECS radiator. For additional information, refer to Section 501-19 .
3. Remove the bolt and remove the upper MECS radiator tube from the MECS cooler.
Motor Electronics Cooler 4164

4. Remove the radiator splash shield.

5. Compress the constant tension clamp and disconnect the MECS radiator hose from the MECS
radiator.
6. Remove the MECS radiator bolts and remove the radiator.



Motor Electronics Pump
Part
1 14A464 Motor Electronics Cooling System (MECS) coolant
pump electrical connector
2 8A567 MECS coolant pump outlet hose
3 15179 MECS coolant punlet hose
4 8C419 MECS pump
2. Disconnect the MECS cooling pump electrical connector.
3. Compress the 2 retainers, remove the MECS pump from the bracket and pull the MECS pump down
to gain access to the constant tension clamps that hold the hoses on.
4. Compress the constant tension clamps and disconnect the inlet and outlet hoses from the MECS
pump.
Motor Electronics Pump 4167


SECTION 307-05A: Automatic Transaxle/Transmission External 2012 Fusion, MKZ, Fusion Hybrid,
Controls - Aisin AW21/6F35 MKZ Hybrid Workshop Manual
SPECIFICATIONS
06/03/2011
Selector lever cable grommet nuts 9 80
Selector lever nuts 20 177

DESCRIPTION AND OPERATION
06/03/2011
External Controls
Part
1 7L010 Selector lever knob (vehicles equipped with a 3.5L
engine)
2 7L010 Selector lever knob (vehicles equipped with a 2.5L
engine)
3 - Transmission Control Switch (TCS) (2.5L engine) (part
of 7L010)
4 7L010 Selector lever knob (vehicles equipped with a 2.5L or
3.0L (4V) engine)
5 - SelectShiftTM switch (2.5L or 3.0L (4V) engine) (part
of 7L010)
6 - Lower selector lever knob bezel (part o
7 7E034 Selector lever bezel (Fusion)
8 7K004 Selector lever assembly (Fusion)
9 7E034 Selector lever bezel (MKZ)
10 7K004 Selector lever assembly (MKZ)
External Controls 4170

12 57809 Selector lever cable grommet

13 - Selector lever cable end (Aisin AW21) (part of 7E395)
14 - Selector lever cable adjustment lock tab (Aisin AW21)
(part of 7E395)
15 7A257 Manual control lever (Aisin AW21)
16 - Selector lever cable end (6F35) (part of 7E395)
17 - Selector lever cable adjustment lock tab (6F35) (part of
7E395)
18 7A257 Manual control lever (6F35)
The transaxle selector lever control linkage consists of:
• a selector lever cable that connects the transaxle range selector lever to the selector lever assembly.
• a Brake Shift Interlock Actuator (BSIA) that is integral to the selector lever assembly.
The selector lever assembly:
• locks the transaxle range selector lever in the PARK position when the ignition switch is in the lock
position.
• requires the transaxle range selector lever to be in the PARK position to turn the ignition switch to the
lock position.
Transmission Control Switch (TCS)-2.5L
Vehicles equipped with a Transmission Control Switch (TCS) have a momentary contact switch located on
the selector lever knob that allows the driver to cancel the operation of Overdrive (O/D) and provides grade
assist.
Grade Assist
• Improves vehicle handling in hilly terrain or mountainous areas by providing additional engine
braking and extends lower gear operation on uphill climbs.
• Additional engine braking is provided through the automatic transaxle shift strategy which reacts to
vehicle inputs including vehicle acceleration, accelerator pedal, brake pedal and vehicle speed.
• The transaxle will select gears that will provide the engine braking desired, based on the vehicle
inputs, this will increase engine rpm during engine braking.
It is recommended to return to DRIVE mode on flat terrain to provide the best fuel economy and transaxle
function. The transaxle returns to O/D and grade assist is cancelled when the TCS is pressed again.
Range Selection-SelectShiftTM
The H-gate selector lever has 5 fixed range positions: P, R, N, D, M and 2 spring-loaded manual positions (-)
and (+).
Transmission Control Switch (TCS)-2.5L 4171

H-Gate Selector-3.5L
The SelectShiftTM switch selector lever has 5 fixed range positions: P, R, N, D, M and a (-) and (+)
SelectShiftTM switch.
SelectShiftTM Switch Selector-2.5L, 3.0L (4V)
Park
In the P position:
• the transaxle is locked and prevents the wheels from turning.

• there is no powerflow through the transaxle.
• the parking pawl locks the final drive.
• the engine may be started.
• the ignition key may be removed.
Reverse
In the R position:
• the vehicle may be operated in a backward direction, at a reduced gear ratio.

• engine braking will occur.
Neutral
In the N position:
• the vehicle is able to roll.

• there is no powerflow through the transaxle.
• the output shaft is not held and is free to turn.
• the engine may be started.
Drive
D is the normal position for most forward driving.
H-Gate Selector-3.5L 4172

D provides:
• automatic shifts - 1st through 6th gears, which includes O/D .

• apply and release of the Torque Converter Clutch (TCC).
Ma/b>
H-Gate
SelectShiftTM Switch
In the M position:
• O/D is cancelled.
• the 6F35 transaxle operates in gears 1st through 5th and the Aisin AW21 operates in gears 1st through
4th.
• grade assist is activated.
• some engine braking may occur.
SelectShiftTM Shift Transmission Selector Lever-H-Gate
The SelectShiftTM shift transmission selector lever gives the driver the ability to change gears up or down
manually as desired.
-M+
• O/D can be selected.
SelectShiftTM Switch Selector-2.5L, 3.0L (4V) 4173

• Moving the selector lever to the forward (-) or backward (+) position will allow the transmission to
utilize the Manual for SelectShiftTM shifting.
• Moving the spring-loaded selector lever forward into (-) in the gate and releasing the selector lever,
the selector lever will return to the M position and the transmission will down shift.
• Moving the spring loaded selector lever backward into (+) in the gate and releasing the selector lever,
the selector lever will return to the M position and the transmission will up shift.
When selecting the appropriate gear in SelectShiftTM transmission mode, the instrument cluster will display
the current selected gear.
The SelectShiftTM shift transmission will make some shifts automatically, primarily to protect the engine
from stalling.
The transmission will not up shift if the redline is approached and must be shifted manually by moving the
selector lever back into (+) and releasing.
SelectShiftTM Transmission Selector Lever-SelectShiftTM Switch
The SelectShiftTM transmission selector lever gives the driver the ability to change gears up or down
manually as desired.
-M+
• O/D can be selected.

• Moving the selector lever to M position will allow the transmission to utilize the Manual Mode for
SelectShiftTM shifting.
• Pressing the SelectShiftTM switch (-) on the selector lever, the transmission will down shift.
• Pressing the SelectShiftTM switch (+) on the selector lever, the transmission will up shift.
When selecting the appropriate ectShiftTM transmission mode, the message center will display the current
selected gear.
The SelectShiftTM shift transmission will make some shifts automatically, primarily to protect the engine
from stalling.
The transmission will not up shift if the redline is approached and must be shifted manually by pressing the
SelectShiftTM switch (+) on the selector lever and releasing.
Gear Availability
SelectShiftTM Switch 4174

SelectShiftTM Switch 4175

DIAGNOSIS AND TESTING
06/03/2011
External Controls
Special Tool(s)


1. Verify the customer concern by operating the system.
<

3. If an obvious cause for an observed or reported concern is found, correct the cause before
proceeding to the next step.
4. If the concern is not visually evident, verify the symptom. GO to Symptom Chart - External
Controls or GO to Symptom Chart - NVH .
• Transmission selector • Smart Junction Box (SJB) fuse 5 (10A)
lever cable • Battery Junction Box (BJB) fuse 47 (10A)
• Manual control lever • Connections
• Selector lever or selector • Wiring harness
lever knob • Brake Pedal Position (BPP) switch
• Brake Shift Interlock Actuator (BSIA)
• SelectShiftTM switch
• Transmission Control Switch (TCS) (vehicles equipped
with a 2.5L engine)
Diagnostic Trouble Code Chart
DTC Component Description Condition Symptom Action

B2572

Brake Shift Brake Shift The associated circuitry Brake shift GO to

Interlock Interlock Output connected to the Smart interlock is Pinpoint
Circuit Failure Junction Box (SJB) or inoperative or does Test A .
fuse, or the SJB itself may not operate
have an issue causing a correctly.
brake shift interlock
concern.
P0815 SelectShiftTM SelectShiftTM The associated circuitry SelectShiftTM GO to
Switch Switch Output connected to the operation is Pinpoint
Circuit Failure SelectShiftTM switch or inoperative or does Test C .
fuse, or the SelectShiftTM not operate
switch itself may have an correctly.
issue causing a fault.
P0816 SelectShiftTM SelectShiftTM The associated circuitry SelectShiftTM GO to
Switch Switch Output connected to the operation is Pinpoint
Circuit Failure SelectShiftTM switch or inoperative or does Test C .
fuse, or the SelectShiftTM not operate
switch itself may have an correctly.
P0819 SelectShiftTM Up And Down The associated circuitry SelectShiftTM GO to
Switch Shift Switch To connected to the operation is Pinpoint
Transmission SelectShiftTM switch or inoperative or does Test D .
Range (TR) fuse, or the SelectShiftTM not operate
Correlation switch itself may have an correctly.
Symptom Chart - External Controls
Symptom Chart - NVH
Symptom Chart - NVH

NOTE: NVH symptoms should be identified using the diagnostic tools that are available. For a list of
these tools, an explanation of their uses and a glossary of common terms, refer to Section 100-04 .
Since it is possible any one of multiple systems may be the cause of a symptom, it may be necessary
to use a process of elimination type of diagnostic approach to pinpoint the responsible system. If this
is not the causal system for the symptom, refer back to Section 100-04 for the next likely system and
continue diagnosis.
• Vibration - a high frequency (20-80 Hz) that is felt through the seat or selector lever. Changes
with engine speed
• Selector lever cable incorrectly routed, grounded out or loose
• CHECK the selector lever cable. REPAIR as necessary.
Electrical Connectors

Selector Lever Harness C3233
Pin
Circuit
Number Circuit Function
1 CET53 Brake Shift Interlock Actuator (BSIA) solenoid power circuit
(BU/OG)
2 CET22 Park position signal to ignition switch
(GY/BN)
3 CET52 (GN) Park position signal to Instrument Cluster (IC)
4 VLN04 Power to PRNDL LED illumination (Fusion/Milan)
(VT/GY)
4 VLN37 Power to PRNDL white lighting illumination (MKZ)
(BU/WH)
5 GD116 Ground
(BK/VT)
6 CET34 Transmission Control Switch (TCS)/Grade Assist button signal return
(BN/GN) (vehicles equipped with a 2.5L engine)
7 CBK03 (GY) TCS /Grade Assist power supply from Battery Junction Box (BJB) fuse
47 (10A) (vehicles equipped with a 2.5L engine)
8 CBK03 (GY) SelectShiftTM sensor power supply from BJB fuse 47 (10A)
9 CET43 (GY) SelectShiftTM sensor upshift circuit
10 CET42 SelectShiftTM sensor downshift circuit
(GN/VT)
11 RE407 SelectShiftTM sensor ground circuit (Fusion/ Milan)
(YE/VT)
11 GD116 SelectShiftTM sensor ground circuit (MKZ)
(BK/VT)
12 - Empty
Pinpoint Tests
Refer to Wiring Diagrams Cell 29 ( Fusion/MKZ , Fusion Hybridybrid ), Transmission Controls

-Aisin AW21 for schematic and connector information.
Refer to Wiring Diagrams Cell 30 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Transmission

Controls-6F35 for schematic and connector information.
Refer to Wiring Diagrams Cell 37 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Shift Interlock for
Selector Lever Harness C3233 4178

PINPOINT TEST A: THE BRAKE SHIFT INTERLOCK SYSTEM DOES NOT RELEASE/LOCK CORRECTLY

A1 CHECK DTCs
♦ Ignition ON. Yes
♦ Connect the scan tool. GO to A2 .
♦ Is DTC B2575 set?
No
The issue may not be in the Brake
Shift Interlock Actuator (BSIA)
electrical system. GO to Symptom
Chart - External Controls in this
section.
A2 CHECK FUSE 5 (10A)
♦ Ignition OFF. Yes
♦ Remove Smart Junction Box (SJB) fuse 5 (10A). GO to A3 .
♦ Check fuse: SJB 5 (10A).
♦ Is the resistance less than 5 ohms? No
GO to A4 .
A3 CHECK THE POWER CIRCUIT FOR
VOLTAGE
♦ Disconnect: Selector Lever C3233. Yes
♦ Ignition ON. GO to A6 .
♦ Measure the voltage between selector lever harness
C3233-1, circuit CET53 (BU/OG), vehicle harness No
side and ground, while applying the brake pedal. GO to A5 .
♦ Is the voltage greater than 10 volts?

A4 CHECK THE POWER CIRCUIT FOR A SHORT
TO GROUND
♦ Disconnect: SJB C2280C. GO to A5 .
♦ Measure the resistance between selector lever
harness C3233-1, circuit CET53 (BU/OG), vehicle No
harness side and ground. REPAIR circuit CET53 (BU/OG)
for a short to ground. CLEAR the
DTCs. TEST the system for normal
operation.
4179
♦ Is the resistance greater than 10,000 ohms?

A5 CHECK THE POWER CIRCUIT FOR AN OPEN
♦ Measure the resistance between the selector lever INSTALL a new SJB . CLEAR the
harness C3233-1, circuit CET53 (BU/OG), vehicle DTCs. TEST the system for normal
harness side and SJB C2280C-23, circuit CET53 operation.
(BU/OG), vehicle harness side.
No
REPAIR circuit CET53 (BU/OG)
for an open. CLEAR the DTCs.
TEST the system for normal
operation.
♦ Is the resistance less than 5 ohms?

A6 CHECK THE GROUND CIRCUIT FOR AN
OPEN
♦ Measure the resistance between selector lever INSTALL a new selector lever.
harness C3233-5, circuit GD116 (BK/VT), vehicle REFER to Selector Lever - Fusion or
harness side and ground. Selector Lever - MKZ in this
section.
No
REPAIR circuit GD116 (BK/VT) for
an open. CLEAR the DTCs. TEST
PINPOINT TEST B: TCS DOES NOT OPERATE CORRECTLY (VEHICLES EQUIPPED WITH A 2.5L ENGINE
ONLY)

B1 CHECK THE IC
♦ Connect the scan tool. Yes
♦ Using the scan tool, monitor the TCS REFER to Section 413-01 for diagnosis of the
PID while cycling the Transmission Instrument Cluster (IC) illumination.
Control Switch (TCS).
♦ Does the TCS PID cycle from No
PINPOINT TEST B: TCS DOES NOT OPERATE CORRECTLY (VEHICLES EQUIPPED WITH 4180
A 2.5L ENGI
depressed to not depressed? GO to B2 .

B2 CHECK FUSE 47 (10A)
♦ Check fuse: Battery Junction Box Yes
(BJB) fuse 47 (10A). GO to B3 .
No
GO to B6 .
B3 CHECK THE POWER CIRCUIT
FOR VOLTAGE
♦ Ignition ON. GO to B5 .
♦ Measure the voltage between selector
lever harness C3233-7, circuit CBK03 No
(GY), vehicle harness side and GO to B4 .
ground.

B4 CHECK THE POWER CIRCUIT
FOR AN OPEN
♦ Disconnect: BJB fuse 47 (10A). Install a new BJB .
♦ Measure the resistance between the
output side of BJB fuse 47 (10A) and No
selector lever harness C3233-7 circuit REPAIR circuit CBK03 (GY) for an open. TEST
CBK03 (GY), vehicle harness side. the system for normal operation.

B5 CHECK THE TCS
A 2.5L ENGI
♦ Measure the resistance between Yes

selector lever harness C3533 pins 6 GO to B7 .
and 7, component side, while cycling
the TCS . No
INSPECT the selector lever wiring harness for
damage. REPAIR the wiring harness as required.
If the selector lever wiring harness is not
damaged, INSTALL a new selector lever knob.
REFER to Selector Lever Knob in this section.
♦ Is the resistance less than 5 ohms

when pressed and greater than
10,000 ohms when released?
B6 CHECK THE SIGNAL CIRCUIT
♦ Disconnect: PCM C175T. REPAIR circuit CBK03 (GY) for a short to
♦ Measure the resistance between ground. INSTALL a new fuse. TEST the system
selector lever harness C3233-6, for normal operation.
circuit CET34 (BN/GN) and ground.
No
REPAIR circuit CET34 (BN/GN) for a short to
ground. INSTALL a new fuse. TEST the system
♦ Is the resistance greater than

10,000?
B7 CHECK THE SIGNAL CIRCUIT
FOR AN OPEN
♦ Disconnect: PCM C175T. Yes
♦ Measure the resistance between INSTALL a new PCM. REFER to Section
selector lever harness C3233-6, 303-14A .
circuit CET34 (BN/GN) and PCM
C175T-31, circuit CET34 (BN/GN). No
REPAIR circuit CET34 (BN/GN) for an open.
♦ Is the resistance less then 5 ohms?
A 2.5L ENGI
PINPOINT TEST C: SELECTSHIFTTM DOES NOT OPERATE CORRECTLY

C1 CHECK FUSE 47 (10A)
♦ Check fuse: Battery Junction Box (BJB) 47 Yes
(10A). GO to C2 .
No
REPAIR circuit CBK03 (GY) for a short
to ground. INSTALL a new fuse.
CLEAR the DTCs. TEST the system for
normal operation.
C2 CHECK THE POWER CIRCUIT FOR
VOLTAGE
♦ Ignition ON. GO to C4 .
♦ Measure the voltage between selector lever
harness C3233-8, circuit CBK03 (GY), vehicle No
harness side and ground. GO to C3 .

C3 CHECK THE POWER CIRCUIT FOR AN
OPEN
♦ Disconnect: BJB Fuse 47 (10A). INSTALL a new BJB .
♦ Measure the resistance between the output side
of BJB fuse 47 (10A) and selector lever No
harness C3233-8 circuit CBK03 (GY), vehicle REPAIR circuit CBK03 (GY) for an
harness side. open. CLEAR the DTCs. TEST the
PINPOINT TEST C: SELECTSHIFTTM DOES NOT OPERATE CORRECTLY 4183


C4 CHECK THE GROUND CIRCUIT
♦ Measure the voltage between selector lever Yes
C3233-8, CBK03 (GY), vehicle harness side GO to C6 .
and C3233-11, circuit RE407 (YE/VT),
vehicle harness side. No
GO to C5 .

C5 CHECK THE GROUND CIRCUIT FOR AN
OPEN
♦ Disconnect: PCM C175B. Yes
♦ Measure the resistance between selector lever INSTALL a new PCM. REFER to
C3233-11, circuit RE407 (YE/VT) and PCM Section 303-14B .
C175B-56, circuit RE407 (YE/VT).
No
REPAIR circuit RE407 (YE/VT) for an
open. CLEAR the DTCs. TEST system

C6 CHECK CIRCUITS FOR A SHORT TO
GROUND

♦ Disconnect: PCM C175B. Yes

♦ Measure the resistance between PCM GO to C7 .
C175B-23, circuit CET43 (GY) and ground.
No
REPAIR circuit CET43 (GY) or circuit
CET42 (GN/VT) for a short to ground.
CLEAR the DTCs. TEST system for
normal operation.
♦ Measure the resistance between PCM

C175B-24, circuit CET42 (GN/VT) and
ground.
♦ Is the resistance greater than 10,000 ohms?

C7 CHECK CIRCUITS FOR AN OPEN
♦ Measure the resistance between PCM Yes
C175B-23, circuit CET43 (GY) and selector INSTALL a new selector lever. REFER
lever C3233-9. to Selector Lever - Fusion in this
section. CLEAR the DTCs. TEST the
system for normal operation. If the
condition still exists, INSTALL a new
PCM. REFER to Section 303-14B .
No
CET42 (GN/VT) for an open. CLEAR
the DTCs. TEST system for normal
operation.
♦ Measure the resistance between PCM
C175B-24, circuit CET43 (GY) and selector
lever C3233-10.

PINPOINT TEST D: SELECTSHIFTTM DOES NOT OPERATE CORRECTLY

D1 CHECK FUSE 47 (10A)
♦ Check fuse: Battery Junction Box (BJB) 47 Yes
(10A). GO to D2 .
No
REPAIR circuit CBK03 (GY) for a short
to ground. INSTALL a new fuse. CLEAR
the DTCs. TEST the system for normal
operation.
D2 CHECK THE POWER CIRCUIT FOR
VOLTAGE
♦ Ignition ON. GO to D4 .
♦ Measure the voltage between selector lever
harness C3233-8, circuit CBK03 (GY), No
vehicle harness side and ground. GO to D3 .
♦ Is the voltage greater than 10 volts? /b>

D3 CHECK THE POWER CIRCUIT FOR AN
OPEN
♦ Disconnect: BJB Fuse 47 (10A). INSTALL a new BJB .
♦ Measure the resistance between the output
side of BJB fuse 47 (10A) and selector lever No
harness C3233-8 circuit CBK03 (GY), REPAIR circuit CBK03 (GY) for an open.
vehicle harness side. CLEAR the DTCs. TEST the system for
normal operation.
PINPOINT TEST D: SELECTSHIFTTM DOES NOT OPERATE CORRECTLY 4186


D4 CHECK THE GROUND CIRCUIT
♦ Measure the resistance between selector lever Yes
C3233-11, circuit RE407 (YE/VT) (Fusion) GO to D5 .
or circuit GD116 (BK/VT) (MKZ) and
ground. No
REPAIR circuit RE407 (YE/VT) (Fusion)
or circuit GD116 (BK/VT) (MKZ) for an
open. CLEAR the DTCs. TEST system

D5 CHECK CIRCUITS FOR A SHORT TO
GROUND
♦ Disconnect: Transmission Control Module Yes
(TCM) C1533. GO to D6 .
♦ Measure the resistance between TCM
C1533-3, circuit CET43 (GY) and ground. No
CET42 (GN/VT) for a short to ground.
CLEAR the DTCs. TEST system for
normal operation.

C1533-4, circuit CET42 (GN/VT) and
ground.

♦ Is the resistance greater than 10,000

ohms?
D6 CHECK CIRCUITS FOR AN OPEN
♦ Measure the resistance between TCM Yes
C1533-3, circuit CET43 (GY) and selector INSTALL a new selector lever. REFER to
lever C3233-9. Selector Lever - Fusion or Selector Lever
- MKZ in this section. CLEAR the DTCs.
TEST the system for normal operation. If
the condition still exists, INSTALL a new
TCM. REFER to Section 307-01A .
No
CET42 (GN/VT) for an open. CLEAR the
DTCs. TEST system for normal operation.
C1533-4, circuit CET43 (GY) and selector
lever C3233-10.
p;


GENERAL PROCEDURES
06/03/2011
Brake Shift Interlock Override
NOTE: If it is necessary to use the override procedure to move the selector lever out of the PARK position, it
is possible that a fuse has blown and the brake lights are not operational. Before driving the vehicle, verify
that the brake lights are working.
This vehicle is equipped with a brake shift interlock feature that prevents the selector lever from being moved
out of PARK when the ignition is in the ON position unless the brake pedal is depressed.
If the selector lever cannot be moved out of the PARK position when the ignition is in the ON position and
the brake pedal is depressed, carry out the following procedure.
Fusion
1. Apply the parking brake.
2. Remove the selector lever trim ring.
3. Remove tenter console trim panel
4. NOTE: Vehicles equipped with a 3.0L/3.5L shown, vehicles equipped with a 2.5L similar.
Using a suitable tool, push the brake shift interlock override forward, apply the brake, press the
selector lever knob button and move the selector lever into NEUTRAL.
5. Start the vehicle.
Brake Shift Interlock Override 4190

6. Install the center console trim panel.
7. Install the selector lever trim ring.
MKZ
8. Remove the access panel.
9. Insert a suitable tool into the access hole, depress the brake shift interlock override mechanism on the
selector lever, apply the brake, depress the button on the selector lever knob and move the selector
lever into NEUTRAL.
11. Install the access panel.


GENERAL PROCEDURES
06/03/2011
Selector Lever Cable Adjustment - Aisin AW21
1. Remove the Air Cleaner (ACL) assembly. For additional information, refer to Section 303-12C .
3. Place the selector lever in DRIVE.
4. Place the manual control lever in DRIVE.

1. Place the manual control lever in PARK.
2. Move the manual control lever counterclockwise 3 detents to the DRIVE position.
5. Release the selector lever cable adjuster lock.

1. Pull out on the adjuster lock tabs.
2. Slide the lock up to unlock the selector lever cable.
6. Align the selector lever cable end to the manual control lever ball stud and install it with the adjuster
unlocked.
Selector Lever Cable Adjustment - Aisin AW21 4193

7. Slide the adjuster tab in place to lock the selector lever cable.
8. Install the ACL assembly. For additional information, refer to Section 303-12C .
9. Verify that the vehicle starts in PARK and NEUTRAL only and that the reverse lamps illuminate in
REVERSE.
Selector Lever Cable Adjustment - Aisin AW21 4194

GENERAL PROCEDURES
06/03/2011
Selector Lever Cable Adjustment - 6F35
2. NOTE: SelectShiftTM shown, Transmission Control Switch (TCS) similar.
Place the selector lever in the D position.
3. Place the manual control lever in the D position.

1. Rotate the manual control lever counterclockwisPARK position.
2. Rotate the manual control lever clockwise 3 detents to the D position.
4. Release the selector lever cable adjuster lock.

1. Pull out on the adjuster lock tabs.
2. Slide the lock up to unlock the selector lever cable.
Selector Lever Cable Adjustment - 6F35 4195

unlocked.
6. Slide the adjuster tab in place to lock the selector lever cable.
REVERSE.


REMOVAL AND INSTALLATION
06/03/2011
Selector Lever Cable
Selector Lever Cable - Aisin AW21
Selector Lever Cable - 6F35 Transaxle
Selector Lever Cable 4198


2 54017A40
3 W707142 Selector lever cable grommet retaining nuts
Removal
1. Remove the heater core and evaporator core housing. For additional information, refer to Section
412-01 .
2. Remove the Restraints Control Module (RCM). For additional information, refer to Section 501-20B .
3. Remove the battery tray. For additional information, refer to Section 414-01 .
4. NOTE: Aisin AW21 shown, 6F35 similar.
Disconnect the selector lever cable end from the manual control lever.
Release the 2 tabs and remove the selector lever cable from the selector lever cable bracket.
6. Disconnect the 2 wiring harness fasteners and position the RCM wiring harness aside.
7. Position the insulation blanket away from the bulkhead to gain access to the 2 selector lever cable
bracket nuts.
Selector Lever Cable - 6F35 Transaxle 4199

8. Remove the 2 selector lever cable grommet nuts and remove the selector lever cable through the
interior of the vehicle.
Installation
1. Position the selector lever cable in place and install the 2 nuts.
2. Position the insulation blanket in place over the selector lever cable grommet.
3. Position back the RCM wiring harness and install the fasteners on the studs.
NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs
are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector
lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the

selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure
that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever
cable end to make sure that the selector lever cable end is correctly installed.
Install the selector lever cable in the bracket. Be sure the tabs are locked in place.
Connect the selector lever cable end on the manual control lever.
7. Install the RCM . For additional information, refer to Section 501-20B .
8. Install the heater core and evaporator core housing. For additional information, refer to Section
412-01 .
9. Adjust the selector lever cable. For additional information, refer to Selector Lever Cable Adjustment -
Aisin AW21 or Selector Lever Cable Adjustment - 6F35 in this section.


06/03/2011
Selector Lever - Fusion
NOTE: Transmission Control Switch (TCS) selector lever shown, SelectShiftTM selector lever similar.

2 14489 Selector lever electrical connector
3 W714098 Selector lever nuts (4 required)
4 7K004 Selector lever assembly
Removal
1. Remove the center console. For additional information, refer to Section 501-12 .
2. Disconnect the selector lever cable end from the selector lever.
3. Release the tab on the selector lever cable and remove it from the selector lever housing.
4. Disconnect the electrical connector.
Selector Lever - Fusion 4203

5. Remove the 4 nuts and remove the selector lever.
Installation
1. Install the selector lever and the 4 nuts.

2. Connect the electrical connector.
3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs
Install the selector lever cable in the selector lever housing.

4. Connect the selector lever cable end to the selector lever.
5. Install the center console. For additional information, refer to Section 501-12 .
6. Adjust the selector lever cable. For additional information, refer to Selector Lever Cable Adjustment -
Aisin AW21 or Selector Lever Cable Adjustment - 6F35 in this section.

06/03/2011
Selector Lever - MKZ

1 14A459 Selector lever bezel electrical connector
2 1181081 Floor console lower trim panel
3 W709955 Floor console screw
6 W714098 Selector lever nuts
7 d>7210 Selector lever
Removal
1. Remove the selector lever bezel. For additional information, refer to Selector Lever Bezel - MKZ in
this section.
2. Remove the PRNDL electrical connector from the RH side of the center console.
Remove the LH and RH center console trim covers.
Selector Lever - MKZ 4206

Remove the LH and RH center console-to-selector lever screws.
5. Disconnect the selector lever cable end from the selector lever ball stu
6. Disconnect the selector lever electrical connector.
7. Remove the 4 selector lever nuts.

8. Position the selector lever off of the studs, release the tab on the selector lever cable and remove it
from the selector lever.
Installation
1. Install the selector lever cable in the selector lever and position the selector lever on the studs.
2. Install the 4 selector lever nuts.

3. Connect the selector lever electrical connector.
4. Connect the selector lever cable end on the selector lever ball stud.

Install the LH and RH center console-to-selector lever screws.
Install the LH and RH center console trim covers.
7. Install the PRNDL electrical connector on the RH side of the center console.
8. Install the selector lever bezel. For additional information, refer to Selector Lever Bezel - MKZ in this
section.
9. Check the selector lever cable adjustment. Make sure that the vehicle starts in PARK and NEUTRAL
and the reverse lamps illuminate in REVERSE. If an adjustment is necessary, refer to Selector Lever
Cable Adjustment - Aisin AW21 in this section.

p;

06/03/2011
Selector Lever Bezel - Fusion
NOTE: Transmission Control Switch (TCS) shown, SelectShiftTM switch similar.

1 54061A16 Selector lever trim ring
2 54045A76 Center console trim panel
3 54045A07 Utility tray
4 14A459 Transmission Control Switch (TCS) electrical
connector (2.5L engine only)
5 - Selector lever knob bezel
6 W701894 Selector lever knob screws
Selector lever
7L010
knob
8 14A459 Selector lever bezel electrical connector
9 7E034 Selector lever bezel
Removal
All vehicles
Selector Lever Bezel - Fusion 4211

2. Remove the center console trim panel.
3. Remove the utility tray from the center console.
4. Disconnect the electrical connector and remove the utility tray.
Vehicles equipped with a 2.5L or 3.0L (4V) engine
5. Disconnect the Transmission Control Switch (TCS) or SelectShiftTM switch electrical connector.
All vehicles
6. NOTE: TCS shown, SelectShiftTM switch similar.
Slide the selector lever knob bezel downward to gain access to the 2 selector lever knob screws.

7. NOTICE: It is necessary to route the Transmission Control Switch (TCS) harness or

SelectShiftTM switch harness out of the selector lever bezel when removing the selector lever
knob.
Remove the 2 screws from the selector lever knob. Remove the selector lever knob and selector lever
knob bezel.
8. Disconnect the selector lever bezel electrical connector.
9. NOTE: Selector lever removed for clarity.
Release the 3 tabs and remove the selector lever knob bezel.
Installation

1. NOTICE: Be sure that the override lever is inserted in the override lever guide or the shift
interlock override button will not work correctly.
NOTE: Selector lever removed for clarity.
Install the selector lever bezel on the selector lever.
• Position the override lever in the override lever guide.

• Make sure that the 3 locking tabs are locked in place.
Install the selector lever bezel on the selector lever and be sure the 3 tabs are locked in place.
All vehicles
3. Connect the selector lever bezel electrical connector.
4. NOTICE: It is necessary to route the Transmission Control Switch (TCS) harness or

SelectShiftTM switch harness out of the selector lever bezel when removing the selector lever
knob.
NOTE: TCS shown, SelectShiftTM switch similar.

Install the selector lever knob on the selector lever and install the screws.
5. Slide the selector lever knob bezel up and install it on the selector lever knob.
Vehicles equipped with 2.5L or 3.0L (4V) engine
6. Connect the TCS or SelectShiftTM switch electrical connector.
All vehicles
7. Position the utility tray in place and connect the electrical connector.

8. Install the utility tray on the center console.


06/03/2011
Selector Lever Bezel - MKZ

1 061A16 Floor console finish moulding
3 7L010 Selector lever knob
5 7B118 Selector lever boot
6 - Selector lever trim ring (part of 7B118)
Re>
1. Remove the LH and RH console finish moldings.
2. Slide the selector lever knob trim ring down to expose the 2 selector lever knob screws.
3. Remove the 2 selector lever knob screws and remove the selector lever knob.
Selector Lever Bezel - MKZ 4218

4. Lift the arm rest, apply the emergency brake, pull directly up on the selector lever bezel and remove it
from the center console.
5. Disconnect the selector lever bezel electrical connector and remove the selector lever bezel.
6. Compress the retention tabs on the selector lever boot and remove the boot from the bottom of the
selector lever bezel.
7. Compress the retention tabs on the selector lever trim ring and remove the trim ring through from the
top of the selector lever bezel.
Installation
1. Install the selector lever trim ring in the selector lever bezel.

2. NOTICE: When installing the selector lever boot, be sure it is in the correct position or the
selector lever boot can not be installed on the selector lever knob. If needed, align the selector
lever knob to the selector lever boot when installing the boot.
Install the selector lever boot in the selector lever bezel.
3. Position the selector lever bezel in place and connect the electrical connector.
4. Position the selector lever bezel in place and install it onto the center console.
5. Position the selector lever knob onto the selector lever and install the screws.
6. Slide the selector lever knob trim ring up and install it on the selector lever knob.

7. Install the LH and RH console finish moldings.

06/03/2011
Selector Lever Knob
NOTE: Transmission Control Switch (TCS) shown, select switch similar.

2 54045A76 Upper console panel
3 14A459 Transmission Control Switch (TCS) electrical
connector (2.5L engine only)
4 - Selector lever knob shroud (part of 7L010)
6 7L010 td>Selector
lever knob
Removal
Selector Lever Knob 4222

3. Disconnect the Transmission Control Switch (TCS) or select switch electrical connector.
All vehicles
4. NOTE: TCS shown, select switch similar.
Slide the selector lever knob shroud downward to gain access to the 2 selector lever knob screws.
5. NOTICE: It is necessary to route the Transmission Control Switch (TCS) harness or select
switch harness out of the selector lever shroud when removing the selector lever knob.
Remove the 2 screws from the selector lever knob. Remove the selector lever knob and selector lever
knob shroud.

Installation
All vehicles
1. NOTICE: It is necessary to route the Transmission Control Switch (TCS) harness or select
switch harness through the selector lever shroud when installing the selector lever knob.
NOTE: TCS shown, select switch similar.
Install the selector lever knob on the selector lever and install the screws.
2. Slide the selector lever knob shroud up and install it on the selector lever knob.

Vehicles equipped with 2.5L or 3.0L (4V) engine
3. Connect the TCS or select switch electrical connector.


SECTION 307-05B: Automatic Transaxle/Transmission 2012 Fusion, MKZ, Fusion Hybrid,

External Controls - Hybrid MKZ Hybrid Workshop Manual
Selector lever cable grommet nuts 9 80
Selector lever nuts 20 177


External Controls

2 - Lower selector lever knob bezel (part of 7L010)
7 - Selector lever cable enof 7E395)
8 - Selector lever cable adjustment lock tab (part of
7E395)
Range Selection
Park
With the range selector in PARK:

• the parking pawl locks the output shaft to the case.

• the ignition key can be removed.
• the ignition switch can be cycled from OFF to START or RUN. The ready indicator light will
illuminate on the Instrument Cluster (IC) when the ignition switch is cycled to the START position.
The ready indicator light is located on the lower right hand corner of the IC .
Ready Indicator Light
Reverse
With the range selector in REVERSE:
• the vehicle may be operated in a rearward direction.

• reversing lamps are illuminated.
• if the ready indicator light is not illuminated, which lights when the ignition switch is cycled to the
START position, there is no reverse gear engagement.
Neutral
With the range selector in NERAL:
• no power flows through the transmission.

• the output shaft is disengaged from the drive wheels.
Drive
The range selector DRIVE position provides:
• low speed driving.

• acceleration.
• cruise conditions.
• deceleration.
Low
The range selector LOW position provides:
• engine braking.
• improved traction on slippery roads.

Brake Shift Interlock System
The brake shift interlock system prevents a shift out of PARK unless the brake pedal is depressed. The brake
shift interlock system has a Brake Shift Interlock Actuator (BSIA) mounted on the selector lever assembly. If
the ignition switch is in the RUN position, the BSIA will allow the selector lever to be moved out of PARK
only when the brake pedal is pressed.
External Controls
The external control of the Electronically Controlled Continuously Variable Transmission (eCVT) is
mechanically controlled by a cable connected to the selector lever and electronically controlled by the TR
sensor (located on the transaxle). The selector lever position determines PARK, REVERSE, NEUTRAL,
DRIVE and LOW modes. For diagnosis, removal and installation of the TR sensor, refer to Section 307-01C .


External Controls
Special Tool(s)


1. Verify the customer concern by operating the system.
3. If an obvious cause for an observed or reported concern is found, correct the cause before proceeding
to the next step.
4. If the concern is not visually evident, verify the symptom. GO to Symptom Chart .
• Transmission selector lever • Smart Junction Box (SJB) fuse 5

cable (10A)
• Manual control lever • Connections
• Selector lever or selector • Wiring harness
lever knob • Brake Pedal Position (BPP)
switch
• Brake Shift Interlock Actuator
(BSIA)
DTC Chart
DTC Component Description Condition Symptom Action

B2572 Brake Shift Brake Shift The associated circuitry Brake shift interlock GO to
Interlock Interlock Output connected to the Smart Junction is inoperative or Pinpoint

Circuit Failure Box (SJB) or fuse, or the SJB does not operate Test A .
itself may have an issue causing a correctly.
brake shift interlock concern.
Symptom Chart - NVH
Symptom Chart - NVH

• Vibration - a high frequency (20-80 Hz) vibration that is felt through the seat or the selector lever.
Changes with engine speed
• Selector lever cable incorrectly routed, grounded out or loose
• REFER to Selector Lever Cable in this section.
• Loose selector lever cable bracket
• CHECK the selector lever cable and bracket for damage and correct assembly. REFER to Selector
Lever Cable in this section. REPAIR as necessary.
• Rattle, noise, buzz or other noise
• Selector lever loose

• Noisy selector lever
• TIGHTEN the selector lever nuts.

• INSTALL a new selector lever. REFER to the Selector Lever in this section.
Electrical Connectors
Selector Lever Harness C3233
Selector Lever Harness C3233 4232

Pin Number Circuit Circuit Function

1 CET53 (BU/OG) Brake Shift Interlock Actuator (BSIA) solenoid power circuit
2 CET22 (GY/BN) Park position signal to ignition switch
3 CET52 (GN) Park position signal to Instrument Cluster (IC)
4 VLN04 (VT/GY) Power to PRNDL LED illumination
5 GD116 (BK/VT) Ground
6 - Empty
7 - Empty
8 D> - Empty
9 - Empty
10 - Empty
11 - Empty
12 - Empty
Pinpoint Test

A1 TEST THE BRAKE LIGHTS
Yes
• Apply the brake pedal and view the brake lights. GO to A2 .
• Do the brake lights illuminate?
No
REFER to Section 417-01 .
A2 TEST SJB FUSE 5 (10A)
Yes
• Check fuse: Smart Junction Box (SJB) 5 (10A). GO to A3 .
No
INSTALL a new fuse. GO to
A3 .
A3 TEST BSIA POWER CIRCUIT
Yes
• Disconnect: Selector Lever Electrical C3233. GO to A6 .
• Ignition ON.
• Measure the voltage between selector lever harness C3233-1, No
circuit CET53 (BU/OG), vehicle harness side and ground, while GO to A4 .
applying the brake pedal.
4233

A4 TEST THE BSIA POWER CIRCUIT FOR A SHORT TO
GROUND
Yes
• Disconnect: SJB C2280C.
• Measure the resistance between selector lever harness C3233-1, No
circuit CET53 (BU/OG), vehicle harness side and ground. REPAIR the circuit. TEST
the system for normal
operation.

A5 TEST THE BSIA POWER CIRCUIT FOR AN OPEN
Yes
• Ignition OFF. INSTALL a new SJB . TEST
• Measure the resistance between the selector lever harness the system for normal
C3233-1, circuit CET53 (BU/OG), vehicle harness side and SJB operation.
C2280C-23, circuit CET53 (BU/OG), vehicle harness side.
No
REPAIR the circuit. TEST
operation.

A6 TEST THE BSIA GROUND CIRCUIT
Yes
• Ignition OFF. INSTALL a new selector
• Measure the resistance between selector lever harness C3233-5, lever. REFER to Selector
circuit GD116 (BK/VT), vehicle harness side and ground. Lever in this section.
No
REPAIR the circuit. TEST
operation.
4234
4235

Brake Shift Interlock Override
NOTE: If it is necessary to use the override procedure to move the selector lever out of the PARK position, it
is possible that a fuse has blown and the brake lights are not operational. Before driving the vehicle, verify
that the brake lights are working.
This vehicle is equipped with a brake shift interlock feature that prevents the selector lever from being moved
out of PARK when the ignition is in the ON position unless the brake pedal is depressed.
If the selector lever cannot be moved out of the PARK position when the ignition is in the ON position and
the brake pedal is depressed, carry out the following procedure:
4. Using a suitable tool, push the brake shift interlock override forward, apply the brake, press the
selector lever knob button and move the selector lever into NEUTRAL.



Selector Lever Cable Adjustment
1. NOTICE: The ignition must be in the OFF position to make sure that the Electronically
Controlled Continuously Variable Transmission (eCVT) and the engine are OFF.
With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02
.
2. Place the selector lever in the D position.
l start="3">
• Remove the bolts and the splash shield.
5. Place the manual control lever in the D position.

1. Rotate the manual control lever counterclockwise to the PARK position.
2. Rotate the manual control lever clockwise 3 detents to the D position.
6. Unlock the adjuster by sliding the locking tab over.
Selector Lever Cable Adjustment 4238

unlocked.
8. Slide the selector lever cable adjuster tab in place to lock the selector lever cable.
REVERSE.
10. Install the splash shield and the bolts.



Selector Lever Cable

2 54017A40 Insulation blanket
3 W707142 Selector lever cable grommet retaining nuts
Removal
100-02 .
412-01 .

6. Release the 2 tabs and remove the selector lever cable from the selector lever cable bracket.
7. Remove the selector lever cable from the retainer.
8. Disconnect the 2 wiring harness fasteners and position the RCM wiring harness aside.
9. Position the insulation blanket away from the bulkhead to gain access to the 2 selector lever cable
bracket nuts.
10. Remove the 2 selector lever cable grommet nuts and remove the selector lever cable through the
interior of the vehicle.

Installation
1. Position the selector lever cable in place and install the 2 nuts.
2. Position the insulation blanket in place over the selector lever cable grommet.
3. Position back the RCM wiring harness and install the fasteners on the studs.
4. Install the selector lever cable in the retainer.

Install the selector lever cable in the bracket. Be sure the tabs are locked in place.
6. Connect the selector lever cable end on the manual control lever.
412-01 .
9. Adjust the selector lever cable.


Selector Lever

3 W714098 Selector lever nuts (4 required)
Removal
1. Remove the center console. For additional information, refer to Section 501-12 .
2. Disconnect the selector lever cable end from the selector lever.
3. Release the tab on the selector lever cable and remove it from the selector lever housing.
Selector Lever 4245

5. Remove the 4 nuts and remove the selector lever.
Installation
1. Install the selector lever and the 4 nuts.

2. Connect the electrical connector.
Install the selector lever cable in the selector lever housing.
Selector Lever 4246

4. Connect the selector lever cable end to the selector lever.
5. Install the center console. For additional information, refer to Section 501-12 .
6. Adjust the selector lever cable. For additional information, refer to Selector Lever Cable Adjustment
in this section.
Selector Lever 4247


Selector Lever Knob

1 - Lower selector lever knob bezel (part of 7L010)
Removal
1. Slide the selector lever knob bezel downward to gain access to the 2 selector lever knob screws.
2. Remove the 2 screws from the selector lever knob. Remove the selector lever knob and the selector
lever knob bezel.

Installation
1. Install the selector lever knob on the selector lever and install the screws.



Selector Lever Bezel

2 54045A76 Center console trim panel
3 54045A07 Utility tray
4 - Selector lever knob bezel
7 14A459 Selector lever bezel electricalctor
Removal
Selector Lever Bezel 4251

3. Remove the utility tray from the center console.
4. Disconnect the electrical connector and remove the utility tray.
5. Slide the selector lever knob bezel downward to gain access to the 2 selector lever knob screws.
6. Remove the 2 screws from the selector lever knob. Remove the selector lever knob and the selector
lever knob bezel.

7. Disconnect the selector lever bezel electrical connector.
Release the 3 tabs and remove the selector lever knob bezel.
Installation
1. NOTICE: Be sure that the override lever is inserted in the override lever guide or the shift
interlock override button will not work correctly.
NOTE: Selector lever removed for clarity.
Install the selector lever bezel on the selector lever.
• Position the override lever in the override lever guide.

• Make sure that the 3 locking tabs are locked in place.

2. Connect selector lever bezel electrical connector.
3. Install the selector lever knob on the selector lever and install the screws.

5. Position the utility tray in place and connect the electrical connector.
6. Install the utility tray on the center console.


SECTION 308-00: Manual Transaxle/Transmission and Clutch - 2012 Fusion, MKZ, Fusion Hybrid,
General Information MKZ Hybrid Workshop Manual
Material

Capacity
High Performance DOT 3 WSS-M6C62-A or -
Motor Vehicle Brake WSS-M6C65-A1
Fluid
PM-1-C (US); CPM-1-C
(Canada)
SAE 75W-90 API GL-4 WSS-M2C203-A1 2.84L (3.0
Gear Oil qts.)
XT-4-QGL
Item Specification
Clutch Disc
Maximum runout 0.7 mm (0.027 in)
Minimum allowable depth to rivet head 0.3 mm (0.011 in)
Clutch pedal free play 1.0-3.0 mm
(0.39-0.118 in)
Clutch Pressure Plate
Flywheel Runout
Pressure Plate Diaphragm Spring Fingers
Maximum clearance 0.3 mm (0.011 in)
Maximum depth 0.6 mm (0.023 in)
Bleeder screw 7 62
Clutch pedal locknut 15 133


Manual Transaxle and Clutch
The transaxle and clutch system consist of the following:
• Six-speed manual transaxle

• Clutch disc
• Clutch pressure plate
• Clutch release hub and bearing
• Clutch hydraulic system
• Clutch pedal
• Flywheel
• Pilot bearing
• Shift controls
The function of the transaxle is to move the vehicle from a rest position to motion. The transaxle uses gears to
adapt the torque to the demands of load and road conditions. It matches engine power to vehicle needs. This
power is delivered from the engine's flywheel to the transaxle. The power is transmitted through a
driver-operated clutch, which allows for engagement and disengagement of the engine to the transaxle.
The transaxle input shaft receives the power when the clutch is engaged. The transaxle then uses a system of
gears to change the speed and torque relationship between the engine crankshaft and the transaxle differential.
The purpose of the clutch is to connect and dnnect a manually operated transaxle, and the halfshafts, from the
engine. This allows starting and stopping the vehicle, shifting and changing vehicle speeds that correspond to
the engine speed through gear changes.
The manual transmission has a tag to identify assemblies for repair purposes. Refer to Section 308-03 for the
transmission tag information.
Manual Transaxle and Clutch 4259

Manual Transaxle and Clutch
Material
Item Specification
SAE 75W-90 API GL-4 Gear Oil WSS-M2C203-A1
XT-4-QGL
Principles of Operation
The function of the transaxle is to move the vehicle from a rest position to motion. The transaxle uses gears to
adapt the torque to the demands of load and road conditions. It matches engine power to vehicle needs. This
power is delivered from the engine's flywheel to the transaxle. The power is transmitted through a
driver-operated clutch, which allows for engagement and disengagement of the engine to the transaxle.
The transaxle input shaft receives the power when the clutch is engaged. The transaxle then uses a system of
gears to change the speed and torque relationship between the engine crankshaft and the transaxle differential.
The clutch master cylinder trans hydraulic fluid pressure to the clutch slave cylinder, when the clutch pedal is
depressed, which in turn moves the clutch release hub and bearing. The clutch hydraulic system uses brake
fluid supplied from the brake master cylinder. The clutch is a single-plate, dry-friction disc with a
diaphragm-style spring pressure plate. The clutch disc has frictional material where it contacts the flywheel
and the clutch pressure plate. The clutch pressure plate applies pressure to the clutch disc, holding it tightly
against the surface of the flywheel.
In the engaged position, the clutch pressure plate diaphragm spring holds the clutch pressure plate against the
clutch disc, so that the engine torque is transmitted to the input shaft. When the clutch is depressed, movement
is transmitted through the clutch hydraulic system.
NOTICE: If transaxle noise is reported, first check the manual transmission fluid level. The vehicle
should not be driven if the manual transmission fluid level is low or damage can occur.
NOTE: Before attempting to rectify any concerns, road test the vehicle to ascertain in which system the
concern falls.
NOTE: If any evaluation or inspection reveals an obvious concern, repair the vehicle.
The technician should have a thorough knowledge of transaxle/clutch operation and accepted general
transaxle/clutch guidelines to detect any problems.
A gear-driven unit will produce a certain amount of noise. Some noise is acceptable and audible at certain
speeds or under various driving conditions. Certain conditions, such as road and weather, will amplify normal
vehicle noise.
The following overview is a guide to diagnose a transaxle/clutch concern:

• Verify and document the customer concern.
♦ During the customer interview, if a leak was noticed or if a leak is the concern, check the
manual transmission fluid. The vehicle should not be driven if the manual transmission fluid
level is low.
• Check the manual transmission fluid level and condition.
• Evaluation of the clutch hydraulic system.
• Evaluation of the clutch.
• Inspect gearshift mechanism.
• Road test.
• Find the cause of the problem and correct it.
Verify Customer Concern
1. Verify and document the customer concern.

1. When was it first noticed?
2. Did it appear suddenly or gradually?
3. Did anything unusual occur that would coincide with it or precede it?
4. Identify when the condition occurs:
♦ Hot or cold vehicle operating conditions
♦ Type of terrain
♦ City/highway driving
♦ Driving at a particular speed
♦ coasting
♦ hard acceleration
♦ Shifting
♦ upshifts
♦ downshifts
♦ in a particular gear
♦ in all gears
♦ Hot or cold ambient temperatures
5. Has the transaxle/clutch been repaired before or components installed?
♦ Check the vehicle service record. Note any repairs.
Check Manual Transmission Fluid Level and Condition
NOTE: The vehicle should not be driven if the manual transmission fluid level is low.
An incorrect manual transmission fluid level may affect the transaxle operation and can result in transaxle
damage. To correctly check and add manual transmission fluid to the transaxle, refer to transaxle draining and
filling in Section 308-03 .
A low manual transmission fluid level can result in poor transaxle shifting, engagement or damage. It can also
indicate a leak in one of the transaxle seals or gaskets.
1. Check the manual transmission fluid condition.

• Observe the color and the odor of the manual transmission fluid. Allow the manual
transmission fluid to drip onto a white cloth and examine the stain. Check the manual
transmission fluid for contamination or metal particles.
♦ Manual transmission fluid should appear nearly clear, similar to clean engine oil.
Evaluation of Clutch Hydraulic System
1. Verify that the brake/clutch hydraulic fluid reservoir is filled to the correct level.
• If the clutch hydraulic fluid level is correct, proceed to clutch check.

• If the rear chamber hydraulic fluid level is low, add fluid as necessary. Check the clutch
hydraulic system for leaks and repair as necessary.
Evaluation of the Clutch
1. Depress and release the clutch pedal slowly to check if the pedal is binding. Make sure the clutch
pedal can be fully depressed and is not restricted by the floor mat. Verify that the pedal return spring
is present and functions correctly.
2. Measure the clutch reserve. With the engine idling, the parking brake on and the clutch pedal up,
gently move the gearshift lever toward reverse gear until gear clash can be heard. Depress the clutch
pedal slowly.
• If the gears cease to clash (full disengage at 25.4 to 38.1 mm (1 to 1.5 in) from the floor), then
hold the pedal at the point of disengagement and increase engine to 4,000 rpm. The clutch
should remain disengaged, clutch OK.
• Any concerns indicate a worn or damaged clutch. Repair as necessary.
3. With the engine idling, move the gearshift lever into 4th gear. Increase the rpm to 2,000 and slowly
release the clutch pedal.
• If the engine stalls, the clutch is OK.
• If the engine does not stall, the clutch is slipping. Repair as necessary.
4. Compare the clutch evaluation results with the following table. The following list of conditions are
typical faults into which clutch concerns will fall.
Inspect the Gearshift Mechanism
1. Inspect the cables for:

• signs of damage.
• broken locks.
• binding.
• cables not fully seated or in hold-down brackets.
• hold-down bracket nuts are loose.
• correct routing.
• correct adjustment.
♦ If the concern is a gear(s) cannot be selected, adjust the cables. Refer to Gearshift
Cable Adjustment in this section.
2. Inspect the gearshift for:

• free play in the gearshift lever (must be no more than 5 mm [0.196 in]). This specification is
for an absolute or "no load" free play.
♦ If the gearshift lever free play is too great, check the gearshift cables and repair as
necessary.
♦ If the gearshift lever free play is OK, adjust the gearshift linkage.
Evaluation of the Transmission
1. During the road test, use the following driving methods to diagnose the problem.
• Start the engine.
• Evaluate the noise in NEUTRAL while the vehicle is parked.
♦ Check whether the noise is present with the clutch fully disengaged (pedal fully
depressed). Check to see if the pedal pulsates abnormally (for clutch diaphragm
finger run out).
♦ Check whether the noise is present with the gearshift in the NEUTRAL position and

the clutch fully engaged (foot off pedal). With the parking brake engaged, move the
gearshift towards the 1st gear position. Apply very slight pressure and note if the gear
noise level is reduced. (for gear rollover noise).
♦ With the clutch fully engaged (foot off pedal), check whether the noise is present as
the engine speed is raised. If the noise reduces, note the engine speed at which this
occurs.
• Listen for any change in noise while depressing and releasing the clutch pedal.
• Listen for any change in noise while changing the engine rpm.
• Drive the vehicle and shift through all of the gear ranges, including reverse. Listen for any
change in noise in a particular gear.
• Drive the vehicle in the gear in which the noise is most noticeable. Depress the clutch pedal
and leave the gear engaged. Listen for any change in noise.
• Drive the vehicle in the gear in which the noise is most noticeable. Depress the clutch pedal
and shift the transmission into NEUTRAL. Release the clutch pedal and allow the vehicle to
coast.
2. Compare the road test results with the following symptom charts. It is a list of conditions that are
typical faults into which the transaxle will fall:
GO to Symptom Chart - Clutch Operation , GO to Symptom Chart - Transaxle or GO to Symptom Chart -

NVH in this section.
Symptom Chart - Clutch Operation
Symptom Chart - Clutch Operation
Symptom Chart - Transaxle
Symptom Chart - Transaxle
Symptom Chart - NVH
Symptom Chart - NVH

NOT NVH symptoms should be identified using the diagnostic tools that are available. For a list of these
• Clutch related vibrations
• Engine component grounding against frame

• Accessory drive belt
• Clutch release bearing
• Flywheel bolts

• Flywheel
• Imbalanced clutch pressure plate
• GO to Pinpoint Test B .
• Excessive noise
• Clutch disc damper damaged

• Transaxle input shaft pilot bearing worn or damaged
• Excessive crankshaft end play
• Clutch release bearing worn or damaged
• Clutch pedal
• Clutch slave cylinder
• GO to Pinpoint Test C . REFER to Section 308-01 . INSPECT the clutch disc for damage. INSPECT
the transaxle input shaft and the transaxle input shaft pilot bearing for wear and damage. CHECK the
crankshaft endplay. Refer to the appropriate section in Group 303 for the procedure. CHECK the
clutch release hub and bearing, and guide tube for wear and damage. REPAIR all components as
necessary. TEST the system for normal operation.
• Clutch rattling noise - occurs with clutch engaged, noise changes/disappears with clutch pedal
depressed
• Flywheel bolts, clutch housing bolts or clutch pressure plate bolts loe
• CHECK the bolts for damage. TIGHTEN the bolts to specifications. REFER to Section 308-01 .
• Clutch squeaking noise - noise is heard when the clutch is operated. Vehicle moves slowly or creeps
when the clutch is disengaged. Can also be difficult to shift into 1st and REVERSE gears
• Pilot bearing seized or damaged
• INSPECT the transaxle pilot bearing for wear or damage. REPAIR as necessary. REFER to Section
308-01 .
• Clutch squeaking noise - occurs with clutch pedal depressed/released
• Worn clutch pedal shaft or bushings
• INSPECT the clutch pedal for wear or damage. REPAIR as necessary. REFER to Section 308-02 .
• Worn, damaged or misaligned clutch release bearing
• INSPECT the clutch release bearing for wear or damage. REPAIR as necessary. REFER to Section
308-01 .
• Clutch grating/grinding noise - occurs when clutch pedal is depressed
• Clutch pressure plate fingers bent or worn
• INSPECT the clutch pressure plate release fingers. INSTALL a new pressure plate as necessary.
• Contact surface of clutch release bearing worn or damaged

• INSPECT the clutch release bearing. REPAIR as necessary. REFER to Section 308-01 .
• Clutchtter - a small amount of noise when clutch pedal is released at initial take off
• Clutch engagement
• Acceptable operating condition.
• Clutch chatter/grabs - in some cases a shudder is felt. Occurs with clutch pedal depressed/released
• Damaged or worn powertrain/driveline mounts
• INSPECT the powertrain/drivetrain mounts. INSTALL new mounts as necessary. Refer to the
appropriate section in Group 303 for the procedure.
• Binding or dragging plunger of the clutch master cylinder or slave cylinder
• CHECK the master and slave cylinder operation. INSPECT the components for damage or wear.
INSTALL a new master or slave cylinder as necessary. REFER to Section 308-02 .
• Grease or oil on the clutch disc facing
• CHECK the input shaft seal and rear main oil seal. REPAIR as necessary. INSTALL a new clutch
disc. REFER to Section 308-01 .
• Clutch disc surface glazed or damaged
• INSPECT the clutch disc surface for a glazed, hardened or damage condition. CARRY OUT a clutch
disc check. INSTALL a new clutch disc as necessary. REFER to Section 308-01 .
• Damaged or worn clutch pressure plate
• INSPECT the clutch pressure plate for wear or damage. INSTALL a new clutch pressure plate as
necessary. REFER to Section 308-01 .
• Flywheel surface damaged or glazed
• INSPECT the flywheel for damage or wear. CARRY OUT a flywheel runout check. INSTALL a new
flywheel as necessary. Refer to the appropriate section in Group 303 for the procedure.
• Clutch chatter noise - noise when clutch pedal is released at initial take off. Clutch is hard to engage
and disengage
• Pilot bearing worn, damaged or not correctly aligned in bore
• INSPECT the clutch pressure plate release fingers for uneven wear, clutch components burnt or a
seized pilot bearing. INSTALL a new pilot bearing as necessary. REFER to Section 308-01 .
• Transaxle rattling/clattering noise - occurs in NEUTRAL or in gear, at idle
• Incorrect manual transmission fluid level or fluid quality
• CHECK that the transaxle is filled to the correct level and with the specified manual transmission
fluid. REFER to Section 308-03 for the manual transmission fluid type.

• Transaxle rattling/clattering noise - noise at idle in NEUTRAL
• Wornugh reverse idler gear
• CHECK the reverse idler gear. REPAIR as necessary. REFER to Section 308-03 .
• Excessive backlash in gears
• CHECK the gear backlash. ADJUST as necessary. REFER to Section 308-03 .
• Worn countershaft gears
• REPAIR as necessary. REFER to Section 308-03 .
• Transaxle whine - a mild whine at extreme speeds or high rpm
• Rotating gears/geartrain
• Acceptable noise.
• Transaxle whine - a high pitched whine, also described as a squeal
• Transaxle gears are worn (hmileage vehicle)
• Result of normal gear wear. REPAIR as necessary. REFER to Section 308-03 .
• Mismatched gear sets
• INSPECT the gear sets for an uneven wear pattern on the face of the gear teeth. REPAIR as
• Damaged or worn transaxle bearing
• INSPECT the transaxle bearings. INSTALL new bearings as necessary. REFER to Section 308-03 .
• Transaxle growling/humming - noise occurs in the forward gears. The noise is more prominent when
the gear is loaded. The problem gear can be located as the noise occurs in a specific gear position
• Gear is cracked, chipped or rough
INSPECT the transaxle gears for damage or wear. INSTALL new gears as necessary. REFER to Section
308-03 .
• Transaxle hissing - noise in NEUTRAL or in forward gears. As bearings wear or break up, the noise
changes to a thumping noise
• Damaged or worn bearings
• Transaxle knocking/thudding - noise at low speeds in forward gears
• Bearings with damaged balls or rollers or with pitted and spalled races

• Transaxle rumble/growl - noise at all speeds in forward gears, monounced in a heavy acceleration
condition
• Damaged or worn transaxle bearing or gears (high mileage vehicles)
• CHECK manual transmission fluid for excessive metal particles. REPAIR as necessary.
Pinpoint Tests
Pinpoint Test A: Clutch Pedal Pulsation
Normal Operation
Clutch pedal feel should be smooth when disengaging and engaging the clutch. Clutch pedal movement is
transmitted by hydraulic fluid pressure, which actuates the clutch release fork and bearing. The clutch release
fork and bearing pushes on the spring center towards the flywheel. The diaphragm spring pivots at the
fulcrum, relieving the load on the clutch pressure plate. Steel spring straps riveted in the clutch pressure plate
cover pull the clutch pressure plate from the clutch disc, disengaging the engine torque from the transmission.

• Clutch disc
• Flywheel
PINPOINT TEST A: CLUTCH PEDAL PULSATION

A1 CHECK THE CLUTCH
PEDAL PULSATION
Yes
• Start the engine. GO to A2 .
• With the transmission in
NEUTRAL, slowly press the No
clutch pedal. VERIFY customer concern.
• Does the clutch pedal
pulsate while being pressed?
A2 INSPECT THE PRESSURE
PLATE BOLTS
Yes
• Inspect the pressure TIGHTEN or INSTALL new bolts. REFER to Section 308-01 .
plate-to-flywheel bolts. TEST the system for normal operation.
• Are any of the pressure
plate-to-flywheel bolts No
loose? GO to A3 .
A3 INSPECT THE CLUTCH
PRESSURE PLATE

• Remove the clutch pressure Yes

plate. Refer to Section 308-01 INSTALL a new clutch pressure plate. REFER to Section 308-01
. . TEST the system for normal operation.
• Inspect the clutch pressure
plate for wear or damage. No
• Are there any signs of GO to A4 .
damage present on the
clutch pressure plate?
A4 INSPECT THE CLUTCH
DISC
Yes
• Check the clutch disc for GO to A5 .
wear or damage.
• Is the clutch disc OK? No
INSTALL a new clutch disc. REFER to Section 308-01 . TEST
A5 INSPECT THE FLYWHEEL
Yes
• Inspect the flywheel for wear VERIFY customer concern.
or damage.
• Is flywheel OK? No
TIGHTEN or INSTALL a new flywheel as necessary. Refer to
the appropriate section in Group 303 for the procedure. TEST the
Pinpoint Test B: Clutch Related Vibrations
Normal Operation
The clutch is designed to transfer the power from the engine to the transmission, which may be either
stationary (starting) or rotating at a different speed (upshifting or downshifting). The clutch is functioning
correctly when both the engine and transmission are rotating at the same speed with the clutch engaged and no
vibrations are felt.

• Engine components
• Accessory drive component
• Flywheel
PINPOINT TEST B: CLUTCH RELATED VIBRATIONS

B1 CHECK FOR ENGINE COMPONENT
GROUNDING
Yes
• With the vehicle in NEUTRAL, position REPAIR any components as necessary.
it on a hoist. Refer to Section 100-02 .
• Check the engine mount interlocks for No
grounding. GO to B2 .
PINPOINT TEST A: CLUTCH PEDAL PULSATION 4268

• Check for the exhaust manifold or other

engine components grounding on the
body or frame.
• Is there evidence of grounding on the
body or frame?
B2 CHECK FOR ACCESSORY DRIVE
VIBRATIONS
Yes
• Ignition OFF. REFER to Section 303-05A to diagnose the accessory
• Remove the accessory drive belt and drive belt components.
check for vibration.
• Does the vibration stop when the INSTALL the accessory drive belt. GO to B3 .
accessory drive belts are removed from
the engine?
B3 CHECK FOR RELEASE BEARING
NOISE
Yes
• Start the engine. INSTALL a new clutch release bearing. REFER to
• Press and hold the clutch pedal but do not Section 308-01 .
disengage the clutch.
• Is a whirring, grating or grinding noise No
present only when the pedal is pushed? GO to B4 .
B4 INSPECT THE FLYWHEEL
Yes
• Remove the clutch disc and pressure GO to B5 .
plate. Refer to Section 308-01 .
• Inspect for loose flywheel bolts. No
• Check for an excessively burnt or TIGHTEN or INSTALL a new flywheel. Refer to the
severely cracked contact surface. appropriate section in Group 303 for the procedure.
• Inspect the flywheel runout. Refer to
Flywheel Runout Check in this section.
• Is the flywheel OK?
B5 CHECK FOR PRESSURE PLATE
IMBALANCE
Yes
• NOTICE: Failure to support the engine REFER to Section 100-04 to diagnose the engine
correctly could result in damage to the vibration concern.
vehicle.
• Support the engine securely. No
• Operate the engine with the transaxle INSTALL a new clutch pressure plate. REFER to
removed. Section 308-01 .
• Is the vibration still present?
Pinpoint Test C: Excessive Noise
Normal Operation
The manual transaxle is controlled by a floor-mounted gearshift lever located in the floor console. Connection
between the floor-mounted gearshift lever and the manual transaxle shift control lever assembly is made
through 2 gearshift cables.
When the operator moves the floor-mounted gearshift lever, that movement is transmitted through 2 gearshift
PINPOINT TEST B: CLUTCH RELATED VIBRATIONS 4269

cables routed through the body to the transaxle. The 2 gearshift cables are attached to the transaxle at the
transaxle shift control lever assembly. The transaxle shift control lever assembly transfers the movement of
the gearshift cables to the shift rods and shift forks located inside the transaxle.
The clutch is designed to transfer the power from the engine to the transmission, which may be either
stationary (starting) or rotating at a different speed (upshifting or downshifting). The clutch is functioning
correctly when both the engine and transmission are rotating at the same speed with the clutch engaged.
Clutch pedal movement is transmitted by hydraulic fluid pressure, which actuates the clutch release hub and
bearing. The clutch release hub and bearing pushes on the spring center towards the flywheel. The diaphragm
spring pivots at the fulcrum, relieving the load on the clutch pressure plate. Steel spring straps riveted in the
clutch pressure plate cover pull the clutch pressure plate from the clutch disc, disengaging the engine torque
from the transmission.

• Internal transaxle components
• Clutch pedal
• Clutch disc
PINPOINT TEST C: EXCESSIVE NOISE

C1 TRANSAXLE NEUTRAL GEAR ROLLOVER
TEST
Yes
• Start the engine and let it idle. REFER to Section 308-03 for transaxle
• NOTE: With the clutch pedal fully pressed, the concerns.
input shaft should stop rotating.
• Press the clutch pedal. No
• Does the noise stop when the clutch pedal is GO to C2 .
pressed?
C2 CHECK THE CLUTCH PEDAL FREE PLAY
Yes
• Press the clutch pedal lightly by hand. GO to C3 .
• Measure the distance the clutch pedal travels.
• Is the clutch pedal travel within 1-3 mm No
(0.039-0.118 in)? ADJUST clutch pedal freeplay. REFER to
Clutch Pedal Freeplay Adjustment in this
section.
C3 CHECK THE CLUTCH SLAVE CYLINDER
Yes
• Inspect the clutch slave cylinder for wear or loss of INSTALL a new clutch slave cylinder.
lubrication. REFER to Section 308-02 .
• Are there signs of wear or loss of lubrication?
No
GO to C4 .
C4 CHECK THE CLUTCH PRESSURE PLATE
Yes
• Inspect the clutch pressure plate for damage or INSTALL a new clutch pressure plate.

material between the pressure plate and flywheel. REFER to Section 308-02 .
• Are there signs of damage?
No
GO to C5 .
C5 CHECK CLUTCH PEDAL SWITCHES
Yes
• Inspect clutch pedal switches for damage or REPLACE or REINSTALL clutch pedal
incorrect installation. switches as necessary.
• Are there any signs of damage or incorrect
installation? No
REFER to Section 308-03 for transaxle
concerns.
Pinpoint Test D: Clutch System Leakage
Normal Operation
Clutch pedal movement is transmitted to the clutch by hydraulic fluid pressure from the master cylinder
reservoir through the hydraulic clutch tubes to the slave cylinder. This actuates the clutch release fork and
bearing. The clutch release fork and bearing pushes on the spring center towards the flywheel. The diaphragm
spring pivots at the fulcrum, relieving the load on the clutch pressure plate. Steel spring straps riveted in the
clutch pressure plate cover pull the clutch pressure plate from the clutch disc, disengaging the engine torque
from the transmission.

• Clutch master cylinder
• Hydraulic tubes
PINPOINT TEST D: CLUTCH SYSTEM LEAKAGE

D1 INSPECT THE CLUTCH MASTER
CYLINDER
Yes
• Inspect clutch master cylinder for GO to D2 .
leakage.
• Is the clutch master cylinder OK? No
REPAIR or INSTALL a new clutch master cylinder as
D2 INSPECT THE CLUTCH SLAVE
CYLINDER
Yes
• Inspect clutch slave cylinder for leaks. GO to D3 .
• Is the clutch slave cylinder OK?
No
REPAIR or INSTALL a new clutch slave cylinder as
D3 INSPECT THE SYSTEM
HYDRAULIC TUBES
Yes
PINPOINT TEST C: EXCESSIVE NOISE 4271

• Inspect clutch hydraulic tubes for CARRY OUT a road test to VERIFY customer
loose or damaged fittings causing complaint.
leakage.
• Are the clutch hydraulic tubes OK? No
REPAIR or INSTALL new components as necessary.
TEST the clutch system for normal operation.
Component Tests
Clutch Slippage
1. Chock the wheels.
3. Depress and release the clutch pedal slowly to check if the pedal is binding.
• If the clutch pedal is not binding, proceed to the next step of this procedure.
• If the clutch pedal is binding, inspect and repair as necessary. Test the system for normal
operation. Proceed to the next step in this procedure, if necessary.
4. Depress the clutch pedal.
5. Start the engine.
6. Shift the transmission to 4th gear.
7. Increase engine rpm to 2,000 and slowly release the clutch pedal. If the engine stalls within 5 seconds,
the clutch is not slipping.
• If the clutch is slipping, remove the clutch disc and pressure plate. Refer to Section 308-01 .
Inspect the clutch disc and pressure plate for wear or damage. Inspect the flywheel for glazing
and damage. Check the clutch release hub and bearing for binding and inspect the guide tube.
Inspect the input shaft for wear and damage. Repair all components as necessary.
Clutch Chatter or Shudder
2. Inspect the engine and transmission mounts for looseness and damage.
• If the mounts are OK, proceed to the next step in this procedure.
• If the mounts are loose or damaged, tighten or install new mounts as necessary. Test the
3. Check for loose bolts that retain the clutch pressure plate to the flywheel.
• If the bolts are tightened to specification proceed to the next step in this procedure.
• If the bolts are loose, tighten the bolts to specification. Refer to Section 308-01 . Test the
4. Remove the clutch disc and pressure plate. Refer to Section 308-01 . Inspect the clutch disc and
pressure plate for wear and damage, and check the clutch disc runout. Refer to Clutch Disc Check in
this section. Inspect the flywheel for glazing and damage. Refer to Flywheel Runout Check in this
section. Inspect the input shaft for wear, damage and eccentricity. Repair all components as necessary.
Clutch Drag
PINPOINT TEST D: CLUTCH SYSTEM LEAKAGE 4272

1. Verify that the clutch hydraulic fluid reservoir is filled to the correct level.
• If the fluid level is correct, proceed to the next step in this procedure.
• If the fluid level is low, add fluid as necessary. Inspect the clutch hydraulic system for leaks
and repair as necessary. Refer to Section 308-02 . Test the system for normal operation.
2. Depress and release the clutch pedal to check for a spongy pedal.
• If the pedal feels OK, proceed to the next step in this procedure.
• If the pedal feels spongy, bleed the clutch hydraulic system. Refer to Clutch System Bleeding
in this section. Test the system for normal operation.
pressure plate for wear and damage, and check the clutch disc runout. Refer to Clutch Disc Check in
this section. Repair all components as necessary.
Hard Shifting
1. Verify that the clutch hydraulic fluid reservoir is filled to the correct level.
• If the fluid level is correct, proceed to the next step in this procedure.
• If the fluid level is low, add fluid as necessary. Check the clutch baldric system for leaks, and
repair as necessary. Refer to Section 308-02 . Test the system for normal operation.
2. Depress and release the clutch pedal to check for a spongy pedal.
• If the pedal feels OK, proceed to the next step in this procedure.
• If the pedal feel spongy, bleed the clutch hydraulic system. Refer to Clutch System Bleeding
in this section. Test the system for normal operation.
pressure plate for wear or damage. Refer to Clutch Disc Check in this section. Check the clutch
release hub and bearing for binding and inspect the guide tube. Inspect the input shaft for wear and
damage. If all of the components are OK, proceed to the next step in this procedure. Otherwise, repair
all components as necessary. Test the system for normal operation.
4. Inspect the transmission housing, shafts, forks and synchronizer assemblies. Refer to Section 308-03 .
Repair all components as necessary.


Clutch Disc Check
Special Tool(s)
Dial Indicator Gauge with Holding Fixture

100-D002 (D78P-4201-B) or equivalent
1. Check the clutch disc lining surface for hardening, the presence of oil or grease.
2. Check for a worn clutch disc lining. Measure the minimum allowable depth to the rivet heads with a
slide caliper.
• If the measurement is less than the minimum, install a new clutch disc.
3. Check for loose clutch disc lining rivets.

• Install a new clutch disc as necessary.
4. Check the clutch disc for cracking, scoring, discoloration or other surface marks.
• Install a new clutch disc if necessary.
5. Using the Dial Indicator Gauge with Holding Fixture, check the maximum allowable runout of the
clutch disc.
• If the runout exceeds the maximum, install a new clutch disc.
6. Use an emery cloth to remove minor imperfections in the clutch disc lining surface.
Clutch Disc Check 4275

7. Check for wear or rust on the splines. If necessary, clean them with an emery cloth.
Clutch Disc Check 4276

Clutch Pedal Freeplay Adjustment
1. Measure the clutch pedal travel.

1. If the measurement is not within specification, turn the clutch pedal adjustment bolt as
necessary.
2. Tighten the clutch pedal locknut to 15 Nm (133 lb-in).
♦ Recheck the measurement.
2. Measure clutch pedal free play.

1. Depress the clutch pedal by hand until the push rod contacts the clutch master cylinder piston.
2. If the measurement is not within specification, loosen the locknut and turn the push rod as
necessary. Tighten the clutch pedal locknut to 15 Nm (133 lb-in).
♦ Recheck the measurement.
Clutch Pedal Freeplay Adjustment 4277

Clutch Pedal Freeplay Adjustment 4278

Clutch Pressure Plate Check
1. Check the clutch pressure plate surface for scoring, cracks or discoloration.
• Minor scratches or discoloration should be removed with a fine emery cloth.
2. Measure the flatness of the clutch pressure plate surface with a straightedge and a feeler gauge.
• Install a new pressure plate as necessary.
3. Check the diaphragm spring fingers for discoloration, scoring and bent or broken segments.
4. Measure the wear of the diaphragm spring fingers.

• Install a new pressure plate as necessary.
Clutch Pressure Plate Check 4279

Flywheel Runout Check
Special Tool(s)

100-D002 (D78P-4201-B) or equivalent
1. Mount the Dial Indicator Gauge with Holding Fixture so that the Dial Indicator Gauge contact point
rides on the clutch disc contact surface.
2. Rotate the flywheel and check the runout.

• If the runout exceeds the maximum runout 0.076 mm (0.0034 in), install a new flywheel.
Flywheel Runout Check 4280

Clutch System Bleeding
Material
Item Specification
High Performance DOT 3 WSS-M6C62-A or
Motor Vehicle Brake Fluid WSS-M6C65-A1
(Canada)
WARNING: Carefully read cautionary information on product label. For emergency medical
information seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if
available. Failure to follow these instructions may result in serious personal injury.
NOTICE: Brake fluid is harmful to ted and plastic surfaces. If brake fluid is spilled onto a painted or
plastic surface, immediately wash it with cold water.
NOTE: When any part of the hydraulic system has been disconnected for repair or new installation, air may
get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after
it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding
equipment.
1. NOTE: Make sure the brake fluid reservoir is to the MAX mark before bleeding the clutch system.
Do not allow the fluid level to drop below 6 mm (0.236 in) of the MAX mark.
Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container
partially filled with clean brake fluid.
2. Press the clutch pedal slowly to the floor.
3. With the clutch pedal held to the floor, loosen the bleeder screw until fluid and air are expelled from
the system.
4. With the clutch pedal held to the floor, tighten the bleeder screw.
5. NOTICE: The clutch hydraulic system fluid is separated from the brake system fluid by a
separate reservoir within the brake reservoir. Do not allow the clutch hydraulic system fluid
level in the reservoir to fall more than 6 mm (0.236 in) below the MAX mark during the
bleeding operation or fluid supply to the clutch release system will be starved, allowing air to
enter the clutch master cylinder. Keep the brake master cylinder reservoir filled with clean,
Clutch System Bleeding 4281

specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic
system.
Repeat Steps 2 through 4 until no air bubbles appear in the fluid.

1 - Brake fluid reservoir
2 - Minimum fluid level for clutch reservoir to fill
3 - Inner clutch fluid reservoir
6. Tighten the bleeder screw.

7. Fill the brake reservoir.
8. Check system for normal operation.
Clutch System Bleeding 4282

Gearshift Cable Adjustment
1. Set the parking brake.
2. Place the gearshift in neutral.
3. Remove the gearshift knob and the floor console finish panel.
4. NOTE: Console removed for clarity.
Disengage the safety lock by sliding it away from the shifter ball stud.
5. NOTE: If the cable lock is difficult to slide out, disconnect the shift cable from the stud, push the
lock from the rear and reattach the shift cable to the ball stud.
Disengage the cable lock by sliding it out from the shift cable end fitting.
6. Allow the gearshift lever to center itself. With the shifter and the transmission in NEUTRAL, push the
cable lock onto the cable.
7. Engage the safety lock by sliding it over the primary shift cable lock.
Gearshift Cable Adjustment 4283

8. Check for normal operation.

SECTION 308-01: Clutch 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual
Material

Capacity
Premium Long-Life Grease ESA-M1C75-B -
XG-1-C or XG-1-K (US);
CXG-1-C (Canada)
Item Specification
Diaphragm spring finger misalignment 0.6 mm (0.023 in) maximum
Description Nm lb-ft
Clutch pressure plate bolts a - -
a Refer to the procedure in this section.

2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop

SECTION 308-01: Clutch
Manual
Clutch
The clutch system includes the following components:
• Flywheel
• Clutch disc
• Clutch release fork
The clutch is a single-plate, dry-friction disc with a diaphragm-style spring clutch pressure plate. The clutch
disc has a hub which is splined to the transmission input shaft. The clutch disc has friction material where it
contacts the flywheel and the clutch pressure plate. The clutch pressure plate applies pressure to the clutch
disc, holding it tightly against the surface of the flywheel. In the engaged position, the diaphragm spring holds
the clutch pressure plate against the clutch disc, so that engine torque is transmitted to the input shaft.
When the clutch pedal is applied, the release bearing pushes the diaphragm spring center of the clutch
pressure plate toward the flywheel. The diaphragm spring pivots at the fulcrum, relieving the load on the
clutch pressure plate. The clutch slave cylinder assists in the effort it takes to relieve the load on the clutch
pressure plate. Steel spring straps riveted to the clutch pressure plate cover pull the clutch pressure plate from
the clutch disc, disengaging the engine torque from the transaxle.
Clutch 4286
SECTION 308-01: Clutch 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual
Clutch
Refer to Section 308-00 .
Clutch 4287

Manual
REMOVAL AND
INSTALLATION
Clutch Disc and Pressure Plate
Special Tool(s)

100-002
Flywheel Holding Tool

303-103 (T74P-6375-A)

Material
Item Specification
Premium Long-Life Grease ESA-M1C75-B
XG-1-C or XG-1-K (US); CXG-1-C
(Canada)

1 7550 Clutch disc
2 7563 Clutch pressure plate
3 - Clutch pressure plate bolt (6 required)
4 7548 Clutch release bearing
5 7515 Clutch release fork
Removal
WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or
friction components. Remove dust using government-approved techniques. Friction component dust
may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if
dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure
may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or
may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure
to follow these instructions may result in serious personal injury.
Clutch Disc and Pressure Plate 4288

Clutch disc and clutch pressure plate
1. Remove the transaxle. For additional information, refer to Section 308-03 .
2. Inspect the clutch pressure plate.

• Check the diaphragm spring fingers for discoloration, scoring, bent or broken segments.
• Using the Dial Indicator Gauge with Holding Fixture, rotate the flywheel and check for sprg
ends that are higher or lower than the rest.
♦ The specification is 0.6 mm (0.023 in) maximum.
3. Using the Flywheel Holding Tool, lock the flywheel to the engine.
4. NOTE: Loosen each bolt, one turn at a time in a star pattern, until spring tension is released.
Using a suitable clutch disc aligner, remove the bolts, the clutch pressure plate and the clutch disc.
5. NOTE: Do not immerse the clutch pressure plate in solvent.
Using a suitable cleaning solution, clean the clutch pressure plate.
6. Inspect the clutch pressure plate surface for burn marks, scores, flatness, ridges or cracks. For
additional information, refer to Section 308-00 .
• Maximum clearance for flatness check is 0.3 mm (0.011 in).
7. NOTICE: If the clutch disc is saturated with oil, inspect the rear engine crankshaft seal or
transmission input shaft seal for leakage. If leakage is found, install a new seal prior to clutch
disc installation. For additional information, refer to Section 303-01A or Section 308-03 .
NOTE: Use an emery cloth to remove minor imperfections in the clutch disc lining surface.
Inspect the clutch disc for the following:

• Oil or grease saturation
• Worn or loose facings
• Warpage or loose rivets at the hub
• Wear or rust on the splines
• Install a new clutch disc if any of these conditions are present.
8. Check the clutch disc runout. For additional information, refer to Clutch Disc Check in Section
308-00 .
9. If necessary, conduct a Flywheel Runout Check. For additional information, refer to Section 308-00 .
Clutch release bearing and clutch release fork
10. Remove the clutch release bearing.
11. Inspect the clutch release bearing for wear or damage.

• Rotate the bearing while applying pressure in the axial direction. If the bearing feels rough,
sticks or has excessive resistance, install a new bearing.
12. Inspect the release bearing guide tube for wear or damage.
• Slide the release bearing on the guide tube. Check for roughness or sticking.
13. Remove the clutch release fork. Inspect the fork for wear or damage.
Installation
Clutch release bearing and clutch release fork
1. Install the clutch release fork.

2. Check for roughness or sticking. If the bearing feels rough, sticks or has excessive resistance, install a
new bearing. Slide the release bearing on the guide tube.
3. Install the clutch release bearing.
Clutch disc and clutch pressure plate
4. Apply a very small amount of grease in the clutch disc hub. Wipe off excess grease to avoid
contaminating the clutch disc and affecting clutch function.
5. Using a suitable clutch disc aligner, position the clutch disc on the flywheel.

1 - Transaxle side
2 - Engine side
6. Position the clutch pressure plate on the flywheel and to the dowels. Install the 6 clutch pressure plate
bolts.
• Tighten the bolts one turn at a time in a star pattern. Tighten to 29 Nm (21 lb-ft).
7. Apply a small amount of grease to:

• the clutch release fork fingers.
• the clutch release fork spring.
• the guide tube.
• the clutch slave cylinder end that contacts the release fork.

8. NOTE: Apply a very small amount of grease to the transmission input shaft end and on the splines.
Install the transaxle. For additional information, refer to Section 308-03 .
9. If the clutch was replaced, use the scan tool to perfohe Misfire Monitor Neutral Profile Correction
procedure, following the on-screen instructions.


Manual
REMOVAL AND
INSTALLATION
Pilot Bearing
Special Tool(s)
Installer, Pilot Bearing

308-105 (T85T-7137-A)
Remover, Pilot Bearing

308-001 (T58L-101-B)
Removal
1. Remove the clutch disc and pressure plate. For additional information, refer to Clutch Disc and
Pressure Plate in this section.
2. Using the Pilot Bearing Remover, remove the pilot bearing.
3. Inspect the pilot bearing for:

• misalignment and looseness in the flywheel.
• needle rollers for scoring, worn or broken needle rollers, inadequate grease or discoloration.
• seal leakage.
Installation
1. NOTE: The pilot bearing can only be installed with the seal facing the transmission. The pilot
bearing is pregreased and does not require additional lubrication. A new pilot bearing must be
installed whenever it is removed.
Using a soft-face hammer and the Pilot Bearing Installer, install the pilot bearing.
2. Install the clutch disc and pressure plate. For additional information, refer to Clutch Disc and Pressure
Pilot Bearing 4293

Plate in this section.
Pilot Bearing 4294


SECTION 308-02: Clutch Controls
Manual
Material

Capacity
High Performance DOT 3 WSS-M6C62-A or -
(Canada)
CXG-1-C (Canada)

Clutch hydraulic tube nut 17 - 150
Clutch master cylinder nuts 21 15 -
Clutch pedal bracket nut 21 15 -
Clutch pedal locknut 10 - 89
Clutch slave cylinder bolts 19 - 168
PCM bolts 10 - 89
PCM bracket nuts 10 - 89
Pilot Bearing 4295


Manual
Clutch Controls
The clutch controls system consists of the following components:
• Clutch pedal
• Clutch master cylinder
• Clutch hydraulic fluid tube
• Clutch release fork
When the clutch pedal is applied, the clutch master cylinder transmits hydraulic fluid pressure to the clutch
slave cylinder. The clutch slave cylinder and the clutch release fork transfer the clutch pedal motion to the
clutch release bearing. The release bearing presses against the pressure plate diaphragm spring, releasing the
clutch disc.
The clutch master cylinder uses brake fluid and shares a common reservoir with the brake master cylinder.
Clutch Controls 4296


Manual
Clutch Controls
For diagnosis and testing of the clutch controls, refer to Section 308-00 .
Clutch Controls 4297


Manual
REMOVAL AND
INSTALLATION
Clutch Pedal
Material
Item Specification
(Canada)

1 - Clutch master cylinder nut (2 required)
2 7A543 Clutch master cylinder
3 - Clutch switch (cruise control cancel)
4 11A152 Clutch Pedal Position (CPP) switch
5 - Clutch pedal bracket nuts
6 - Retaining clip
7 - Clutch pedal and bracket assembly
8 - Master cylinder push rod clevis
9 - Clevis bushing
10 - Clevis pin
11 - Clutch pedal locknut
12 - Master cylinder push rod
13 - Retaining clip
Removal
1. Remove the battery and the battery tray. For additional information, refer to Section 414-01 .
2. Remove the PCM.

1. Disconnect the electrical connectors.
Clutch Pedal 4298

2. Remove the 2 PCM bolts.
3. Remove the 3 PCM bracket nuts and the bracket.
4. Remove the clutch master cylinder nut.
5. Working under the instrument panel, disconnect the clutch switch (cruise control cancel)
electrical connector.
6. Disconnect the Clutch Pedal Position (CPP) electrical connector.
7. Remove the clutch master cylinder nut and the clutch pedal bracket nut.
8. Remove the clutch pedal and bracket assembly.

Installation
1. NOTE: Make sure to align the push rod into the clutch master cylinder piston as the pedal
assembly is installed.
Install the clutch pedal and bracket assembly
• Apply a small amount of grease to the:

♦ clevis bushing.
♦ end of the clutch switch.
♦ end of the master cylinder push rod.
2. Working under the instrument panel, connect the clutch switch (cruise control cancel)
3. Install the clutch master cylinder nut and the clutch pedal bracket nut.
Clutch Pedal 4299

4. Connect the CPP electrical connector.

5. Install the clutch master cylinder nut.
6. Install the PCM bracket and the 3 PCM bracket nuts.

7. Install the PCM.

1. Install the 2 PCM bolts.
♦ Tighten to 10 Nm (89 lb-in).
2. Connect the electrical connectors.
8. Install the battery tray and the battery. For additional information, refer to Section 414-01 .
Clutch Pedal 4300

Clutch Pedal 4301


Manual
REMOVAL AND
INSTALLATION
Clutch Master Cylinder
Material
Item Specification
(Canada)

1 - Clutch hydraulic tube nut
2 - Clutch hydraulic tube
3 7A543 Clutch master cylinder
4 - Clutch master cylinder nut
5 2K478 Clutch system reservoir
6 - Clutch master cylinder reservoir hose
7 7519 Clutch pedal and bracket
8 - Clutch master cylinder nut
Removal
WARNING: Carefully read cautionary information on product label. For EMERGENCY

MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products
call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. Failure to follow these instructions may result in serious personal injury.
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions will
help prevent system contamination, brake component damage and the risk of serious personal injury.
Clutch Master Cylinder 4302

WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure
to follow this instruction may result in serious personal injury.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If
brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.
get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after
it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding
equipment.
1. Working under the instrument panel, remove the clutch master cylinder nut.
2. Using a suitable suction tool, remove the brake fluid to just below the clutch reservoir hose.
4. Remove the PCM.

1. Disconnect the electrical connectors.
2. Remove the 2 PCM bolts.
5. Remove 3 PCM bracket nuts and the PCM bracket.

6. Disconnect the clutch master cylinder-to-clutch hydraulic tube.
7. Disconnect the clutch master cylinder reservoir hose.
8. Remove the clutch master cylinder nut.
9. Remove the clutch master cylinder assembly.
Installation
1. Install the clutch master cylinder assembly.
2. Install the clutch master cylinder nut.

3. Working under the instrument panel, install the clutch master cylinder nut.

4. Connect the clutch master cylinder reservoir hose.
5. Connect the clutch master cylinder-to-clutch hydraulic tube.

• Tighten the clutch hydraulic tube nut to 17 Nm (150 lb-in).
6. Install the PCM bracket and 3 PCM bracket nuts.

7. Install the PCM.

1. Install the 2 PCM bolts.
♦ Tighten to 10 Nm (89 lb-in).
2. Connect the electrical connectors.
8. Install the battery tray. For additional information, refer to Section 414-01 .
9. Bleed the clutch hydraulic system. For additional information, refer to Section 308-00 .



Manual
REMOVAL AND
INSTALLATION
Clutch Slave Cylinder
Material
Item Specification
(Canada)
CXG-1-C (Canada)

1 7A508 Clutch slave cylinder
2 - Clutch slave cylinder bolts (2 required)
3 7T504 Clutch hydraulic tube
4 - Clutch hydraulic tube nut
Removal
WARNING: Carefully read cautionary information on product label. For EMERGENCY

MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products
call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. Failure to follow these instructions may result in serious personal injury.
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions will
help prevent system contamination, brake component damage and the risk of serious personal injury.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If
brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.
Clutch Slave Cylinder 4307

get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system afte
has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding
equipment.
1. Using a suitable suction tool, remove the brake fluid to just below the clutch reservoir hose.
2. Disconnect the clutch hydraulic tube.
3. Remove the 2 clutch slave cylinder bolts and the clutch slave cylinder.
Installation
1. NOTE: Apply a small amount of grease on the end of the slave cylinder push rod.
Install the clutch slave cylinder and the 2 clutch slave cylinder bolts.
2. Connect the clutch hydraulic tube.


3. WARNING: Do not allow the brake master cylinder to run dry during the bleeding
operation. Master cylinder may be damaged if operated without fluid, resulting in degraded
braking performance. Failure to follow this instruction may result in serious personal injury.
Bleed the air from the system. For additional information, refer to Section 308-00 .

SECTION 308-03: Manual 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid
Transaxle/Transmission Workshop Manual
Material

Capacity
CXG-1-C (Canada)
SAE 75W-90 API GL-4 Gear WSS-M2C203-A1 2.84L (3.0
Oil qts.)
XT-4-QGL
Silicone Gasket and Sealant WSE-M4G323-A4 -
TA-30
TA-25
Item Specification
Differential
Preload 1.4-1.9 Nm
(13-17 lb-in)
Secondary shaft gear runout (maximum) 0.015 mm (0.0006 in)
Side gear and pinion gear backlash 0.050-0.150 mm
(0.0020-0.059 in)
End Play
Input shaft 0.00-0.06 mm
(0.00-0.0024 in)
Mainshaft 0.00-0.06 mm
(0.00-0.0024 in)
Gear Clearance
1st Gear End Play
Clearance 0.05-0.28 mm
(0.002-0.011 in)
Maximum 0.33 mm (0.012 in)
(0.007-0.018 in)


3rd Gear Thrust Clearance
(0.002-0.007 in)
4th Gear End Play
(0.007-0.014 in)
5th Gear Thrust Clearance
(0.0040-0.0086 in)
6th Gear Thrust Clearance
(0.0040-0.0086 in)
Runout
Input shaft gear runout (maximum) 0.05 mm (0.001 in)
Reverse idler gear runout (maximum) 0.04-0.14 mm
(0.0016-0.0060 in)
Reverse idler gear component dimension 57.0-57.5 mm
(2.244-2.263 in)
Shift Fork and Hub Sleeve Clearance
Reverse Shift Fork and Hub Sleeve
Standard 0.10-0.40 mm
(0.004-0.015 in)
Clearance Between 1st/2nd Shift Fork and Hub Sleeve
(0.004-0.017 in)
Clearance Between 3rd/4th Shift Fork and Hub Sleeve
(0.004-0.015 in)
Clearance Between 5th/6th Shift Fork and Hub Sleeve

(0.003-0.014 in)
Synchronizer Ring Clearance
Clearance Between Synchronizer Ring and Flank Surface of
Gear
Standard 0.80 mm (0.031 in)
Secondary Shaft to Gear Clearance
Gear Shaft Outer Diameter Gear Inner Diameter Clearance

1st 39.445-39.470 mm 39.500-39.525 mm 0.030-0.080 mm
(1.553-1.554 in) (1.555-1.556 in) (0.002-0.003 in)

2nd 34.945-34.965 mm 35.000-35.025 mm 0.05-0.09 mm
(1.376-1.377 in) (1.378-1.379 in) (0.002-0.003 in)

3rd 35.945-35.970 mm 36.000-36.025 mm 0.030-0.080 mm
(1.415-1.416 in) (1.417-1.418 in) (0.002-0.003 in)

4th 30.945-30.970 mm 31.000-31.025 mm 0.030-0.080 mm
(1.218-1.219 in) (1.220-1.221 in) (0.001-0.003 in)

5th 33.945-33.970 mm 34.000-34.025 mm 0.030-0.080 mm
(1.3365-1.3373 in) (1.3386-1.3395 in) (0.0012-0.0031 in)
Differential Shim Thickness (7067)
mm Inch
0.1 0.003
0.20 0.007
0.25 0.009
0.30 0.011
0.35 0.013
0.40 0.015
0.45 0.017
0.50 0.019
0.55 0.021
0.60 0.023
0.65 0.025
0.70 0.027

0.75 0.029
0.80 0.031
0.85 0.033
0.90 0.035
0.95 0.037
1.0 0.039
1.05 0.041
1.10 0.043
1.15 0.045
1.20 0.047
Primary Shaft Gear Shim Thickness (7L172)
mm Inch
0.30 0.011
0.35 0.013
0.40 0.015
0.45 0.017
0.50 0.019
0.55 0.021
0.60 0.023
0.65 0.025
0.70 0.027
0.75 0.029
0.80 0.031
0.85 0.033
0.90 0.035
0.95 0.037
1.0 0.039
Secondary Shaft Gear Shim Thickness (7L172)
mm Inch
0.20 0.007
0.25 0.009
0.30 0.011
0.35 0.013
0.40 0.015
0.45 0.017
0.50 0.019

0.55 0.021
0.60 0.023
0.65 0.025
0.70 0.027
Reverse Thrust Washer Thickness
mm Inch
2.04 0.080
2.09 0.082
2.14 0.084
2.19 0.086
2.24 0.088
2.29 0.090
2.34 0.092
2.39 0.094

Anchor bolt 10 - 89
Breather cover bolts 10 - 89
Case cover bolts 45 33 -
Clutch housing-to-oil pan bolts 48 35 -
Clutch slave cylinder bolts 20 - 177
Clutch tube hydraulic line bracket bolts 22 16 -
12 - 106
Drain plug 49 36 -
Electronic Power Assist Steering (EPAS) ground bolt 12 - 106
Fill plug 49 36 -
Oil pan-to-clutch housing bolts 48 35 -
Primary and secondary shaft locknuts 160 118 -
Reverse idler shaft lock bolt 22 16 -
Roll restrictor bracket bolts 90 66 -
Roll restrictor bracket through bolt 90 66 -
Roll restrictor-to-subframe through bolt 90 66 -
Shim selection set bolts 33 -
Shift control selector plate bolts a - - -
Shift detent bolt 18 - 159
Shift gate bolt 13 - 115

Shift lever assembly bolts 22 16 -

Shift rail guide bolt 12 - 106
Splash shield bolts 9 - 80
Stabilizer bar link nuts 40 30 -
Steering shaft pinch bolt 20 - 177
Subframe bracket-to-body bolts 103 76 -
45 33 -
Transaxle rear support insulator bolt and nuts 80 59 -
Transaxle rear support insulator-to-frame bolts (upper and lower) (4 required) 63 46 -
Transaxle-to-engine bolts 48 35 -
Upper transaxle-to-engine bolts 48 35 -
Vehicle Speed Sensor (VSS) bolt 9 - 80

Manual Transaxle
Manual Transaxle
The G6M 6-speed manual transaxle features the following:
• Fully synchronized 6-speed transaxle

• Synchronized reverse gear
• Six forward speeds and one reverse speed
• An aluminum main case, clutch housing and structural cover
The function of the transmission is to move the vehicle from a rest position to motion. This is done by
transferring the engine torque, through the transaxle, to the front wheels. The transmission input shaft receives
power when the clutch is engaged. Torque flows through the input shaft to the drive gear. The forward gears
are selected by a synchronizer mechanism. The helical-cut forward gears are in constant mesh with the
corresponding gears on the opposing shaft. Reverse gears have helical-cut teeth and are engaged through the
reverse idler gear.
External Shift Linkage
between the floor-mounted gear shift lever and the manual transaxle gear shift control mechanism is made
through 2 shift cables. The clutch pedal disengages the clutch allowing the transaxle to be shifted from one
gear to another.
Internal Shift Linkage
The G6M manual transaxle is shifted internally by 4 shift forks. The reverse gear shift fork shifts in and out of
the reverse gear. The 1st/2nd, 3rd/4th and 5th/6th shift forks control all forward gear shifts.
Reverse Gear
The reverse idler gear is mounted on a reverse idler gear shaft supported at one end in the clutch housing and
at the other in the transaxle case by a reverse idler shaft lock bolt.
When the reverse idler gear slides on the reverse idler gear shaft, it engages the reverse drive gear on the input
shaft and the reverse gear on the output shaft. The driving gear is part of the input shaft and the reverse gear is
machined on the outside diameter of the 1st/2nd synchronizer sleeve.
When the reverse idler gear rotates on the reverse idler gear shaft, it reverses the power flow to the output
shaft.
To engage the reverse idler gear, the motion of the shift fork is transferred to the reverse gearshift lever
through the shift gate. The reverse gearshift lever is mounted on a meshlock plunger that allows it to act as a
fulcrum. When the reverse gearshift selector arm moves its end of the shift fork, the opposite end slides the
reverse idler gear into engagement with the input shaft and output shaft reverse gears.
Differential
Manual Transaxle 4316

The ends of the differential are supported on tapered roller differential bearings. The cups for these
differential bearings are seated in the transaxle case and the flywheel housing. Differential bearing preload is
set using a selective differential bearing shim that is installed under the differential bearing cup in the
transaxle case.
The differential includes the differential side gears and the shaft mounted differential pinion gears. Direct
contact between the gears and the differential case is prevented by the differential side gear thrust washers
installed under the gears. The differential pinion shaft is held in position by a differential pinion shaft lock pin
that extends through the end of the differential pinion shaft and the differential case.
The speedometer drive gear is also mounted on the differential case. It is located between the tapered roller
differential bearing and the differential case. A tab on the speedometer drive gear and a matching slot in the
differential case prevent the speedometer drive gear from spinning on the differential case.

Manual Transaxle

Transaxle Draining and Filling
Material
Item Specification
XT-4-QGL

1 - Transaxle drain plug
2 - Transaxle fill plug
100-02 .
2. Remove the drain plug and drain the fluid.
3. Install a new washer and the drain plug.

4. NOTE: Prior to removal, clean the area of the fill plug.
Remove the fill plug.
5. NOTE: Do not overfill the transaxle. This may result in increased operating temperature or cause
transaxle fluid to be forced out of the case.
Fill the transaxle with the recommended fluid.
Transaxle Draining and Filling 4319

1 - Correct level
2 - Low level
6. Install a new washer and fill plug.

p;
Transaxle Draining and Filling 4320

Halfshaft Seal
Special Tool(s)

308-119 (T87C-77000-H)
Remover, Stator Case Bearing

307-163 (T86P-70043-A)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
XT-4-QGL

1 4B436 LH halfshaft assembly
2 7052 Halfshaft oil seal
3 - RH intermediate shaft
4 7052 Halfshaft oil seal
NOTICE: New halfshaft oil seals should be installed any time the halfshafts are removed. Failure to
install new halfshafts seals may result in transaxle oil leak(s) and damage to the transmission may
occur.
1. Remove the transaxle drain plug and drain the fluid.
2. Remove the RH intermediate shaft or LH halfshaft. For additional information, refer to Section
205-04 .
Halfshaft Seal 4321

3. Using the Slide Hammer with the Stator Case Bearing Remover, remove the RH intermediate shaft oil
seal or the LH halfshaft oil seal.
Installation
1. Using the Halfshaft Oil Seal Installer, install the RH intermediate shaft or the LH halfshaft oil seal.
2. NOTE: Do not allow t splines on the halfshaft to touch the oil seal.
Install the RH intermediate shaft or LH halfshaft. For additional information, refer to Section 205-04 .
3. Fill the transaxle to specification. For additional information, refer to Transaxle Draining and Filling
in this section.
Halfshaft Seal 4322

Transaxle Rear Support Insulator
Special Tool(s)
Support Bar, Engine

303-F072

1 10723 Battery tray
2 - Battery tray bolts (2 required)
3 - Power Distribution Box (PDB) bolt (2 required)
4 - PDB nut
5 - PDB electrical connectors
6 14A067 PDB assembly
7 - Clutch hydraulic tube
8 5410494 Splash shield
9 W707398-S Splash shield bolt (7 required)
10 6F020 Transaxle rear support insulator
11 W710645-S Transaxle rear support insulator nut (2 required)
12 W711487-S Transaxle rear support insulator bolt
13 W709234-S Transaxle rear support insulator-to-frame bolt (4
required)
Removal
Transaxle Rear Support Insulator 4323

100-02 .
1. Remove the 7 splash shield bolts and the splash shield.
3. Remove the 2 lower transaxle rear support insulator bolts.
5. Remove the 2 Power Distribution Box (PDB) bolts and the lower nut. Pull the PDB upward to unclip
the pushpin.
6. Disconnect the 2 electrical connectors.
7. Install the Engine Support Bar.

8. Remove the clutch hydraulic tube spring clip. Push downward on the clutch tube to release it from the
bracket.
9. Remove the clutch hydraulic tube from the plastic retainer.
10. NOTE: If one or both of the mount studs are removed or come out, do not reinstall the old stud(s).
Install a new stud(s). Make sure the studs are properly seated in the case, even if they were not
replaced.
Remove the remaining 2 transaxle rear support insulator-to-frame bolts, the 2 transaxle rear support
insulator nuts and the transaxle rear support insulator-to-transaxle bolt.
11. Remove the transaxle rear support insulator.
Installation
1. Install the transaxle rear support insulator.
replaced.
Install the 2 upper transaxle rear support insulator-to-frame bolts.
3. Install the 2 transaxle rear support insulator nuts and the transaxle rear support insulator bolt.
4. Install the clutch hydraulic tube into the plastic retainer.
5. Install the clutch hydraulic tube spring clip. Push upward on the clutch tube to attach it to the bracket.

7. Position the PDB in place. Connect the 2 electrical connectors.
8. Push the PDB downward to clip the pushpin. Install the 2 PDB bolts and the lower nut.
9. Install the battery tray and battery. For additional information, refer to Section 414-01 .
10. Install the 2 lower transaxle rear support insulator-to-frame bolts.

11. Install the splash shield and the 7 splash shield bolts.


Vehicle Speed Sensor (VSS)
Material
Item Specification
XT-4-QGL

1 14487 Vehicle Speed Sensor (VSS) electrical connector
2 - VSS bolt
3 17271 VSS
100-02 .
2. Disconnect the Vehicle Speed Sensor (VSS) electrical connector.
3. Remove the VSS bolt.

4. Remove the VSS .

• Discard the O-ring.
Vehicle Speed Sensor (VSS) 4328


• Apply clean manual transaxle fluid to a new O-ring and install it on the VSS .
Vehicle Speed Sensor (VSS) 4329

Transaxle
Special Tool(s)
Powertrain Lift
300-OTC1585AE or equivalent
Support Bar, Engine

303-F072
100-02 .
3. Remove the Air Cleaner (ACL) assembly. For additional information, refer to Section 303-12A .
4. Disconnect the shift cables from the transaxle shift control lever, using a suitable tool to lightly pry
them off the transaxle shift control lever.
5. NOTICE: Carefully pry the retainer on the shift cables. Do not damage the shift cable retainers.
Using a small screwdriver push from the back.
Disconnect the shift cables from the transaxle bracket.
Transaxle 4330
6. Install the Engine Support Bar.
7. Detach the wire harness from the transaxle.
8. Remove the 3 upper transaxle-to-engine bolts.
replaced.
Remove the transaxle rear support insulator nuts and the transaxle rear support insulator bolt.
steering wheel.
Section 501-20B .
Transaxle 4331
14. NOTE: If disassembly of the transaxle is required, remove the drain plug and drain the transaxle.
Remove the drain plug and drain the transaxle.
15. Once fluid has drained, install the drain plug.

16. Remove the 2 clutch tube hydraulic line bracket bolts.
17. Remove the 2 bolts and position the clutch slave cylinder aside.
18. Disconnect the reverse lamp switch electrical connector.
Transaxle 4332
20. Disconnect the Output Shaft Speed (OSS) electrical connector.
23. Remove the 2 roll restrictor bracket bolts.
Transaxle 4333
28. Remove the LH halfshaft and the intermediate shaft. For additional information, refer to Section
205-04 .
29. Disconnect the 2 in-lineElectronic Power Assist Steering (EPAS) system electrical connectors at the
front of the subframe.
30. Detach the 2 EPAS system wiring harness pin-type retainers from the subframe.
31. Detach the EPAS system wiring harness pin-type retainer from the subframe under the LH fender
splash shield.
32. Remove the bolt and the EPAS system wiring harness ground from behind the RH splash shield.
Transaxle 4334
Remove the nuts and separate the stabilizer bar links from the struts.
34. Position the Powertrain Lift under the subframe assembly.
Remove the rear subframe nuts and the subframe brackets.
Transaxle 4335
40. Remove the clutch housing-to-oil pan bolt.
41. Remove the 2 oil pan-to-clutch housing bolts.
42. Remove the remaining 4 transaxle-to-engine bolts.
43. Move the transaxle away from the engine and lower it from the vehicle.
Transaxle 4336
Transaxle 4337
DISASSEMBLY Procedure revision date: 06/03/2011
Transaxle
Special Tool(s)
Holding Fixture
307-003 (T57L-500-B)
Turning Torque Socket, Transmission

308-160 (T88C-7025-GH)
NOTE: Clean the transaxle exterior before disassembly.
NOTE: Clean all removed parts and all sealing surfaces with solvent, and dry with compressed air.
NOTE: Clean out all holes and passages with compressed air and verify that there are no obstructions.
1. Mount the transaxle to the Holding Fixture.
2. Remove the clutch release fork and bearing.
NOTE: May need to use a screwdriver to pry the clutch release fork off the anchor bolt, if needed.
1. Remove the clutch release bearing.

2. Remove the clutch release fork and diaphragm.
3. If necessary, remove the anchor bolt.
Transaxle 4338
4. Remove the bolt and the Vehicle Speed Sensor (VSS).
5. Remove the reversing lamp switch wiring harness retainer bolt and reversing lamp switch.
6. Shift the transaxle into the NEUTRAL position.
7. Remove the 9 case cover bolts and the case cover.
8. Remove and discard the 5th/6th gear shift fork roll pin.
9. Shift the 5th/6th gear shift fork to 5th.
Transaxle 4339
10. NOTE: Do not reuse locknuts.
Remove the primary and secondary shaft locknuts.
1. Using the Transmission Turning Torque Socket, keep the input shaft from turning.
2. Using a punch, release the locking tabs from the shafts. Remove and discard the primary and
secondary shaft locknuts.
11. NOTICE: Make sure the tabs of the suitable tool are securely positioned on the gear or damage
to the gear may occur.
Using a suitable tool, remove the bearing and 6th gear from the secondary shaft.
12. NOTICE: Make sure the tabs of the suitable tool are securely positioned on the gear or damage
to the gear may occur.
Using a suitable tool, remove the bearing and 6th gear from the primary shaft.
Transaxle 4340
13. Remove the gear sleeve.
14. Remove the 5th/6th shift fork and synchronizer assembly.
15. Remove the spacer and the gear sleeve.
16. Remove the 5th speed primary and secondary gears.
NOTE: Make sure the transaxle is in neutral.
Transaxle 4341
17. Remove the reverse idler shaft lock bolt and shift rail guide bolt.
18. Remove the shift detent bolt, spring and ball.
19. Remove the 15 transaxle case bolts and separate the transaxle case.
• After separating the transaxle cases, position the removed case on its side. Use care not to
damage the funnel.
20. Remove the funnel bolt and the funnel.
21. Remove the magnet.
22. Remove the shift lever shaft pin, then remove the shift lever shaft and shift fork selector lever.
Transaxle 4342
23. Remove the shift gate bolt.
24. Remove the shift control shaft and remove the shift gate.
25. Move the shift forks upward into 2nd and 4th gears.
26. Remove the reverse idler gear assembly and shift fork.
27. Rotate the main shift control shaft clockwise to free the interlock from the 1-2 and 3-4 shift forks.
28. Raise the main shift control shaft until it clears the bore in the transaxle case and remove the main
shift control shaft assembly, shift forks.
Transaxle 4343
29. Remove the primary and secondary shafts at the same time.
30. Remove the differential.
31. For further disassembly of the transaxle case, refer to Transaxle Case in this section.
Transaxle 4344
SUBASSEMBLIES
5th/6th Gear
1. Inspect the 5th and 6th gear synchronizer cones, gear teeth and rings for wear or damage. Replace as
necessary.
2. NOTE: Set the synchronizer ring squarely on the gear and measure around the circumference.
Using a feeler gauge, while applying pressure and rotating the synchronizer ring, measure the
clearance between the 5th gear synchronizer ring and the flank surface of the gear. The measurement
should be the same around the entire circumference. Replace the synchronizer ring if less than the
minimum specification.
5th Gear Synchronizer Ring Clearance
Standard Minimum
1.50 mm (0.059 in) 0.80 mm (0.031 in)
3. NOTE: Set the synchronizer ring squarely on the gear and measure around the circumference.
Using a feeler gauge, while applying pressure and rotating the synchronizer ring, measure the
clearance between the 6th gear synchronizer ring and the flank surface of the gear. The measurement
should be the same around the entire circumference. Replace the synchronizer ring if less than the
minimum specification.
6th Gear Synchronizer Ring Clearance
Standard Minimum
1.50 mm (0.059 in) 0.80 mm (0.031 in)
5th/6th Gear 4345

4. Measure the clearance between the clutch hub sleeve and the shift fork. Replace if it exceeds the
maximum specification.
• Inspect the clutch hub sleeve and clutch hub operation. Replace if there is a malfunction.
5th/6th Gear Clutch Hub Sleeve and Shift Fork Clearance
Standard Maximum
0.10-0.36 mm (0.004-0.014 in) 0.86 mm (0.033 in)
5. Using a telescoping gauge, measure the ID of the 5th gear. Using a micrometer, measure the OD of
the gear sleeve.
6. Measure the telescoping gauge to determine if the gear to the gear sleeve clearances are within
specifications. If not within specifications, replace as needed.
7. Using a telescoping gauge, measure the ID of the 6th gear. Using a micrometer, measure the OD of
the gear sleeve.
5th/6th Gear 4346

8. Measure the telescoping gauge to determine if the gear to the gear sleeve clearances are within
specifications. If not within specifications, replace as needed.
5th and 6th Gear Oil Clearance
Gear Gear ID Gear Sleeve OD Clearance

5th 34.00- 33.945- 0.030-
34.025 mm (1.3386- 33.970 mm (1.3365- 0.80 mm
1.3395 in) 1.3373 in) (0.001-
0.003 in)
6th 34.00- 33.945- 0.030-
34.025 mm (1.3386- 33.970 mm (1.3365- 0.80 mm (0.001-
1.3395 in) 1.3373 in) 0.003 in)
5th/6th Gear 4347

5th/6th Gear 4348

SUBASSEMBLIES
Input Shaft
Special Tool(s)

100-002 (TOOL-4201-A)
Installer, Differential Bearing Cup

308-155 (T88C-7025-DH)
Installer, Transaxle Bearing Cone

307-181 (T87C-77000-D)
Plate, Bearing/Oil Seal

205-090 (T75L-1165-B)
Puller, Bearing
205-D064 (D84L-1123-A) or equivalent
Shaft Protector Set

205-DS004 (D80L-625-A) or equivalent
Material
Item Specification
XT-4-QGL

1 7025 Bearing
Input Shaft 4349

2 7017 Input shaft

3 7101 3rd gear
4 - Double cone (part of 7Z018)
5 - Inner cone (part of 7Z018)
6 7Z018 Synchronizer blocking ring (part of blocking ring set)
7 7109 Synchronizer blocking springs (part of 7124)
8 7A044 Synchronizer hub insert (part of 7124)
9 7105 Synchronizer hub (part of 7124)
10 7106 Synchronizer sleeve (part of 7124)
11 7124 Synchronizer hub assembly
12 7064 Snap ring
13 - Double cone (part of 7Z018)
14 - Inner cone (part of 7Z018)
15 7110 4th gear
16 7025 Bearing
Disassembly
1. Measure the input shaft clearances.

1. Measure the clearance between the 3rd and 2nd gears. Third gear thrust clearance is 0.05-0.20
mm (0.001-0.007 in).
2. Measure the clearance between 4th gear and the bearing cone. Fourth gear endplay is
0.17-0.37 mm (0.006-0.014 in).
2. NOTE: When pressing off components, hold the shaft so it does not fall.
NOTE: Use the Shaft Protector Set to pamage to the shaft.
Using the Bearing Puller and a suitable press, press off the bearing.
• Discard the bearing.

• Always install new bearings and cups as a set.
Input Shaft 4350

3. NOTE: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order
that they were removed.
Remove 4th gear and the synchronizer blocking ring.
4. Remove and discard the snap ring.
5. NOTICE: The synchronizer blocking rings are not interchangeable. Make sure to keep them in
the order that they were removed.
NOTE: Use the Shaft Protector Set to prevent damage to the shaft.
Using the Bearing Puller and a suitable press, press off the synchronizer hub assembly, the
synchronizer blocking ring and 3rd gear as an assembly.
Input Shaft 4351

NOTE: Using a paint pen, mark the hub to sleeve position for reassembly.
6. Disassemble the synchronizer assembly.

1. Remove the synchronizer blocking spring.
2. Remove the opposite synchronize spring.
3. Remove the synchronizer hub inserts.
4. Separate the synchronizer hub from the sleeve.
♦ Inspect all synchronizer components for wear and damage. Install a new synchronizer
as necessary.
7. NOTE: Use the Shaft Protector Set to prevent damage to the shaft.
Using the Bearing Puller and a suitable press, press off the bearing.

Input Shaft 4352

8. Using the Dial Indicator Gauge with Holding Fixture, measure the input shaft gear runout.
• Inspect the input shaft for worn or damaged gears. Install a new input shaft as necessary.
• Input shaft gear maximum runout is 0.05 mm (0.001 in).
9. Set the synchronizer ring set squarely on the gear, then measure around the circumference.
• Measure the clearance from the side of the gear.
♦ Synchronizer ring clearance is 0.80-1.50 mm (0.031-0.059 in).
• Inspect for smooth engagement with the gear.
• Inspect for worn or damaged teeth. Install new components as necessary.
10. Inspect the synchronizer hub.

• Inspect for worn or damaged splines, synchronizer insert groove or end surface.
• Inspect for smooth hub sleeve movement when it is installed.
11. Measure the clearance between the 3rd/4th synchronizer hub and its shift fork.
• Shift fork and hub sleeve clearance is 0.10-0.90 mm (0.003-0.035 in).
Assembly
NOTE: Do not reassemble the input shaft dry.
1. Lubricate all input shaft components with the recommended transmission lubricant during
reassembly.
Using the Bearing/Oil Seal Plate, Transaxle Bearing Cone Installer and a suitable press, press on the
new bearing.
Input Shaft 4353

3. Install 3rd gear.
4. Assemble the synchronizer.

1. Position the synchronizer hub and sleeve together.
2. Install the synchronizer hub inserts.
3. Install the synchronizer blocking spring.
4. Rotate the synchronizer and install the opposite synchronizer blocking spring.
5. Assemble 3rd gear blocking ring set and synchronizer assembly
NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove
and synchronizer hub inserts.
NOTE: Make sure to have the ridge facing the 3rd gear when installing the synchronizer hub
assembly.
NOTE: Make sure that the 4 grooves in the synchronizer hub are facing the 3rd gear.
NOTE: Make sure 3rd gear rotates freely on the shaft.
Using the Bearing/Oil Seal Plate, Differential Bearing Cup Installer and a suitable press, press the
input shaft onto the 3rd gear synchronizer blocking ring and synchronizer assembly.
Input Shaft 4354

7. NOTE: Invert the input shaft.
Install a new snap ring.
8. Assemble the 4th gear blocking ring set.
9. Assemble the 4th gear synchronizer assembly.
10. Install the 4th gear blocking ring set and synchronizer assembly into the input shaft.
11. NOTICE: Press the bearing onto the input shaft by the inner race only. Pressing on the outer
race will damage the bearing.
NOTE: Make sure 4th gear rotates freely on the shaft.
NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring tab and
synchronizer hub inserts.
Using the Bearing Puller and a suitable press, press on a new bearing.
12. NOTE: If not within specifications, disassemble and reassemble the input shaft assembly.
Measure the input shaft clearances.
1. Measure the clearance between the 3rd and 2nd gears.
Input Shaft 4355

♦ 2nd gear end play is 0.018-0.46 mm (0.007-0.018 in), maximum end play is 0.51 mm
(0.02 in).
2. Measure the clearance between the 4th gear and the bearing cone.
♦ 4th gear end play is 0.17-0.37 mm (0.006-0.014 in), maximum end play is 0.42 mm
(0.016 in).
Input Shaft 4356

SUBASSEMBLIES
Output Shaft
Special Tool(s)
Bearing Puller

100-002 (TOOL-4201-A)

308-155 (T88C-7025-DH)
Installer, Transaxle Bearing Cone

307-181 (T87C-77000-D)
Plate, Bearing/Oil Seal

205-090 (T75L-1165-B)
Material
Item Specification
XT-4-QGL

1 7F431 Output shaft bearing
2 7061 Output shaft
3 - Spacer
4 - Friction dampener
5 7100 1st gear
6 - Synchronizer inner cones
7 - Synchronizer outer cones
Output Shaft 4357

8 7107 Synchronizer blocking rings

9 - 1st/2nd gear synchronizer assembly
10 - Synchronizer key springs
11 - Synchronizer key
12 - 1st/2nd clutch hub
13 - Clutch hub sleeve (reverse gear)
14 7064 Snap ring
15 7102 2nd gear
16 - Friction damper cone
17 - Secondary 3rd gear
18 7064 Snap ring
19 - Secondary 4th gear
20 7025 Bearing
Disassembly
NOTE: When pressing off components, hold the shaft so it does not fall.
1. Measure the output shaft clearances.

1. Measure the clearance between 1st gear and the differential drive gear. First gear endplay is
0.05-0.33 mm (0.001-0.012 in).
2. Measure the clearance between 2nd gear and secondary 3rd gear. Second gear endplay is
0.18-0.51 mm (0.007-0.02 in).
2. Using the Bearing Puller and a suitable press, press off the bearing and 4th gear.
Output Shaft 4358

4. Using the Bearing Puller and a suitable press, press off the 3rd gear and 2nd gear.
5. NOTE: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order
Remove the synchronizer blocking ring, the synchronizer inner cone and the synchronizer outer cone.
7. NOTE: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order
Using the Bearing/Oil Seal Plate and a suitable press, press off the synchronizer hub, synchronizer
blocking ring and 1st gear.
8. NOTE: Using a paint pen, mark the hub to sleeve position for reassembly.
Output Shaft 4359

Disassemble the synchronizer assembly.
1. Remove the synchronizer blocking spring.

2. Rotate the synchronizer and remove the opposite spring.
3. Remove the hub inserts.
4. Separate the synchronizer hub from the sleeve.
♦ Inspect all synchronizer components for wear or damage. Install a new synchronizer
as necessary.
9. NOTE: Always install new bearings and cups as a set.
Using the Bearing Puller and a suitable press, press off the bearing and discard.
10. Using a Dial Indicator Gauge with Holding Fixture, measure the output shaft gear runout.
• Inspect the output shaft for wear or damage.
• Inspect the output shaft for a plugged oil passage.
• Maximum output shaft gear runout is 0.015 mm (0.0006 in).
• Install a new output shaft as necessary.
11. Set the synchronizer ring squarely in the gear, then measure around the circumference.
• Measure the clearance from the side of the gear.
♦ Synchronizer ring clearance is 0.80-1.50 mm (0.031-0.059 in).
• Inspect for smooth engagement with the gear.
• Inspect for worn or damaged teeth or tapered surface. Install new components as necessary.
Output Shaft 4360

12. Inspect the synchronizer hub.
• Inspect for worn or damaged splines, synchronizer insert groove or end surface.
• Inspect for smooth hub sleeve movement when it is installed.
13. Measure the clearance between the 1st/2nd synchronizer hub and its shift fork.
• Shift fork and hub sleeve clearance is 0.10-0.95 mm (0.003-0.037 in).
Assembly
1. NOTE: Do not reassemble the output shaft dry. Apply lubricant throughout the assembly procedure.
Lubricate all output shaft components with the recommended transmission lubricant during
reassemble.
2. Using the Bearing/Oil Seal Plate, Transaxle Bearing Cup Installer and a suitable press, press on a new
bearing.
3. If installing a new output shaft, using a suitable press, install the new spacer.
4. Install the friction dampener.
5. Assemble the synchronizer.

1. Position the synchronizer hub to the sleeve.
2. Install the hub inserts.
3. Install the blocking spring.
4. Rotate the synchronizer and install the opposite blocking spring.
6. Assemble the 1st gear blocking ring set and synchronizer.
7. NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove
and synchronizer hub inserts to prevent damage.
Using the Bearing/Oil Seal Plate, Differential Bearing Cup Installer and a suitable press, press on the
1st gear, the synchronizer blocking ring and synchronizer assembly.
Output Shaft 4361

8. Invert the shaft.
9. Install a new snap ring.
10. NOTE: Make sure 1st gear rotates freely.
Install the synchronizer blocking ring, the synchronizer outer cone and the synchronizer inner cone.
11. Install the friction damper cone onto 2nd gear.
12. Install 2nd gear.
13. Using a suitable tool, press on 3rd gear.

• Make sure the slots on 3rd gear are aligned with the fingers on the friction damper cone.
14. NOTE: Make sure 2nd gear rotates freely.
Output Shaft 4362

Install a new snap ring.
15. Using a suitable tool, press on 4th gear.
16. NOTICE: Only press on the inner race of the bearing or damage may occur to the bearing.
Invert the output shaft in the press. Using a suitable tool, install a new bearing.
17. NOTE: If not within specifications, disassemble and reassemble the output shaft assembly.
Measure the output shaft clearances.
1. Measure the clearance between 1st gear and the differential drive gear. First gear endplay is
0.05-0.33 mm (0.001-0.012 in).
2. Measure the clearance between 2nd gear and 3rd gear. Second gear endplay is 0.18-0.51 mm
(0.007-0.02 in).
Output Shaft 4363

Output Shaft 4364

SUBASSEMBLIES
Differential
Special Tool(s)
Adapter Set, Step Plate

Bearing Puller

100-002 (TOOL-4201-A)

308-162 (T88C-77000-EH)
Push/Puller Set

1 4221 Differential bearings
2 17285 Speedometer drive gear
3 4241 Differential pinion shaft lock pin
4 4026 Differential
5 4228 Differential side gear thrust washers
6 4236 Differential side gears
7 4230 Differential pinion gear thrust washers
8 4215 Differential pinion gears
Differential 4365
9 4211 Differential pinion shaft

Disassembly
1. Inspect the differential for wear or damage.

• Inspect for damaged or worn gears.
• Inspect for worn or damaged differential bearings.
• Install new components as necessary.
2. Remove the differential side gears and thrust washers.

• Rotate the differential side gears to remove.
3. Remove and discard the differential pinion shaft lock pin.
4. Remove the differential pinion shaft, the differential pinon gears and the thrust washers.
5. Using the Step Plate Adapter Set, Bearing Puller and the Push/Puller Set, remove the differential
bearing.
6. Remove the speedometer drive gear.
Differential 4366
7. Rotate the differential assembly. Using the Step Plate Adapter Set, Bearing Puller and the Push/Puller
Set, remove the other differential bearing.
Assembly
1. Align the locking tabs and install the speedometer drive gear.
2. NOTICE: Press the differential bearings onto the differential case by the inner race only.
Pressing on the outer race will damage the bearing.
Using the Differential Bearing Cup Installer and a suitable press, press the differential bearing onto
the differential case.
Differential 4367
3. Rotate the differential case. Using the Differential Bearing Cup Installer and a suitable press, press on
the differential bearing.
4. Install the differential pinion gears and thrust washers.
5. Install the differential pinion shaft.
6. Install the new differential pinion shaft lock pin.
7. Install the differential side gears and thrust washers.
8. Measure the differential backlash using the following steps in the following sequence:
1. Install the LH and RH halfshafts in the differential.
2. Support the halfshafts on V-blocks as shown.
3. Using the Dial Indicator Gauge with Holding Fixture, measure the backlash of both pinion
gears.
♦ If not within specification, replace worn and damaged parts.
Differential 4368
Differential 4369
SUBASSEMBLIES
Transaxle Case
Special Tool(s)
Handle
205-153 (T80T-4000-W)
Installer, Clutch Housing Oil Seal

308-057 (T77J-7025-G)

308-162 (T88C-77000-EH)

308-119 (T87C-77000-H)
Remover, Stator Case Bearing

307-163 (T86P-70043-A)
Slide Hammer
100-001 (T50T-100-A
Transaxle Case Exploded View
Transaxle Case 4370


1 7025 Bearing race
2 7052 Oil seal
3 7F431 Bearing race
4 7L276 Funnel
5 7479 Shift control selector plate
6 7K470 Vent cover
7 7034 Vent
8 17271 Vehicle Speed Sensor (VSS)
9 7052 Oil seal
10 - Bearing race
11 7B096 Drain plug
12 99562 Drain plug washer
13 7025 Bearing race
14 - Selective shim (part of 7L172)
15 7025 Bearing race
16 - Selective shim (part of 4067)
17 7052 Oil seal
18 7277B Dust boot (part of 7439)
19 7Z262 Spring pin
20 99576 Snap ring (part of 7439)
21 - Selector lever (part of 7439)
22 - Bracket (part of 7439)
23 7202 Shift lever
24 7277A Dust boot
25 7B220 Key
26 7B125 Control rod end
27 7G046 Spring and washer
28 7358 Shift lever shaft
29 7288 Oil seal
30 7A174 Oil funnel
31 7141 Bushing
Disassembly and Assembly
1. Place the transaxle clutch housing on a bench.
2. Remove the 2 vent cover bolts and the vent cover.
3. Using the Slide Hammer and Stator Case Bearing Remover, remove the differential bearing cup.
Transaxle Case Exploded View 4371

• Inspect the cup for wear or damage. Install a new cup as necessary.
4. Using a screwdriver, remove and discard the differential seal.
5. Remove the input shaft bearing cup.

6. Using a screwdriver, remove and discard the input shaft oil seal.
7. Remove the output shaft bearing cup and the funnel.

8. Remove the shift control selector plate bolts and the shift control selector plate.

9. Working on the transaxle case:

1. Remove the 2 shift lever assembly bolts and separate the boot from the case.
2. Separate the shift arm, boot and bushing from the shift lever assembly.
10. Remove the control arm bolt.
11. Pull the shift lever outward, then remove the washer, spring and the control arm.
12. Remove the control arm key.
13. Remove the shift lever from the case.

• Inspect all components for wear or damage. Install new components as necessary.
14. Inspect the shift lever bushing and replace if necessary.

15. Remove the shift lever boot.
16. Remove the shift lever seal.
17. Remove the input shaft bearing cup and shims.

18. Remove the output shaft bearing cup and shims.

19. Using the Slide Hammer and Stator Case Bearing Remover, remove the differential bearing cup and
shims.
20. Remove and discard the differential oil seal.

Assembly
1. Do not install the following components into the transaxle case at this time. These components will be
installed during final assembly.
• Input shaft bearing cup and shim
• Output shaft bearing cup and shim
• Differential bearing cup and shim
• Funnel
2. Working on the transaxle clutch housing side, install the vent cover and the 2 vent cover bolts.
3. Using the Clutch Housing Oil Seal Installer, install a new input shaft seal.
4. Install the input shaft bearing cup into the clutch housing.
5. Align and install the funnel and the output shaft bearing cup into the clutch housing.

6. Using the Differential Bearing Cup Installer and Handle, install the differential bearing cup into the
clutch housing.
7. Using the Halfshaft Oil Seal Installer, install new halfshaft seals.
8. Install the shift control selector plate.

• Tighten the bolt on the left to 10 Nm (89 lb-in).
• Tighten the bolt on the right to 28 Nm (21 lb-ft).
9. Install the shift lever boot.
10. Install shift lever seal into the case.
11. Install the shift lever rod into the case. Install the control arm key.

12. NOTE: Use care not to let the washer fall off the rod.
Install the control arm, the spring and the washer. Push the assembly inward. Align the control arm
bolt with the notch on the shift lever rod. Install the bolt.
13. Install the shift lever assembly.

1. Install the 2 shift lever assembly bolts and attach the boot and bushing to the case.
♦ Tighten to 22 Nm (16 lb-ft).
2. Attach the shift arm, boot and bushing to the shift assembly.

SUBASSEMBLIES
Reverse Idler Gear

1 - Roll pin
2 - Reverse idler gear support
3 - Washer
4 - Reverse idler gear
5 - Thrust washer
6 - Reverse clutch hub sleeve
7 - Reverse synchronizer ring
8 - Synchronizer key spring
10 - Friction damper
11 - Reverse idler gear shaft
12 - Needle bearing
13 - Thrust washer
14 - Clip
Disassembly
1. Remove the clip.
2. Remove the thrust washer.
Reverse Idler Gear 4378

3. Remove the needle bearing.
4. Remove the reverse idler gear.
5. Remove the friction damper.
6. Remove the reverse synchronizer assembly.
7. Remove the reverse idler gear washer.

8. Remove the reverse idler gear.
9. Remove the reverse idler gear washer.
Assembly
1. Install the reverse idler gear washer.
2. Install the reverse idler gear.
3. Install the reverse idler gear washer.
4. Install the reverse synchronizer assembly.

• Reverse clutch hub inspection.
♦ Inspect the clutch hub sleeve and hub operation. Install new components as
necessary.

♦ Inspect the gear teeth for damage, wear, and cracks. Install new components as
necessary.
♦ Measure the clearance between the hub sleeve and shift forks. If it exceeds the
maximum specification replace the hub sleeve and shift fork as a set.
Reverse Clutch Hub Sleeve and Shift Fork Clearance
Standard Maximum
0.10 mm-0.40 mm (0.003-0.015 in) 0.90 mm (0.035 in)
• Reverse synchronizer ring inspection.

♦ Inspect the synchronizer teeth for damage, wear and cracks. Install new components
as necessary.
♦ Inspect the tapered surface for wear or cracks. Install new components as necessary.
♦ NOTE: Set the synchronizer ring squarely on the gear and measure around the
circumference.
Measure the clearance between the synchronizer ring and the flank surface on the
gear. If it is less than minimum specification, replace the synchronizer ring.
Reverse Synchronizer Ring Clearance
Standard Minimum
1.50 mm (0.059 in) 0.80 mm (0.031 in)
5. Install the friction damper onto the reverse idler gear.
6. NOTE: The reverse idler gear is not serviced separately. A kit consisting of the output shaft reverse
gear, the countershaft reverse gear and the reverse idler gear is available for service. All 3 gears in the
kit must be installed. The replacement gears are not compatible with the existing gears.
Install the reverse idler gear.
• Reverse idler gear inspection.

♦ Inspect the synchronizer cones for wear. Install new components as necessary.

♦ Inspect the gear teeth for damage, wear and cracks. Install new components as
necessary.
♦ Inspect the synchronizer ring matching teeth for damage or wear. Install new
components as necessary.
7. Install the needle bearing.
8. Install the thrust washer.
9. Install the clip.
10. Measure the reverse idler gear component dimension.
Reverse Thrust Washer Thickness
mm Inch
2.04 0.080
2.09 0.082
2.14 0.084
2.19 0.086
2.24 0.088
2.29 0.090

2.34 0.092
2.39 0.094
• If the reverse idler gear component dimension is not within specification, install a thrust
washer of the correct thickness.

ASSEMBLY Procedure revision date: 06/03/2011
Transaxle
Special Tool(s)

100-002 (TOOL-4201-A)
Handle
205-153 (T80T-4000-W)
Holding Fixture
307-003 (T57L-500-B)
Installer, Differential Bearing Cup Replacer

308-162 (T88C-77000-EH)
Rotator, Differential
308-165 (T88C-77000-L)
Shim Selection Set

308-161 (T88C-77000-C)
Shim Selection Set

308-164 (T88C-77000-JF)
Turning Torque Socket, Transmission

308-160 (T88C-7025-GH)
Material
Item Specification
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30
Transaxle 4384

1 7505 Clutch housing
2 - Control rod
3 - Control end
4 - 1st/2nd shift fork
5 - Control lever
6 - Interlock lever
7 - 3rd/4th shift fork
8 - Inner shift lever
9 - Spring pin
10 - Push pin component and spring
11 4026 Differential
12 - Secondary shaft gear assembly
13 - Primary shaft gear assembly
14 - Shift fork and shift rod assembly
16 - Reverse shift fork
17 - 5th/reverse shift rod end
18 - 5th/reverse shift rod
19 7L027 Magnet
20 7F116 Crank lever component
21 - O-ring
22 7C355 Crank lever shaft
Transaxle 4385
23 - Pin
24 7005 Transaxle case component
25 7G072 Neutral switch
26 - Push pin component
27 - Detent spring
g bolt and washer
29 15520 Reversing lamp switch
30 - Lock bolt
31 - Shift rail guide bolt
32 - Reverse idler shaft lock bolt
33 - Clutch hub
34 - Clutch hub sleeve
36 - Spacer
37 - Gear sleeve
38 - 5th gear
39 - 5th gear synchronizer
41 - 5th/6th clutch hub
42 - 5th/6th shift fork
45 - 6th gear synchronizer
46 - 6th gear
47 - Gear sleeve
48 - Bearing (secondary shaft)
49 - Bearing (primary shaft)
50 7N170 Locknut (secondary shaft)
51 7N170 Locknut (primary shaft)
52 7222 Rear cover
NOTE: Whenever the transaxle has been disassembled, the bearing preload must be and differential bearing
preload can be adjusted by selecting shims to insert between the bearing races and the case.
1. Install the input shaft.
2. Install the bearing cup onto the bearing.
Transaxle 4386
3. Install the Shim Selection Set.
4. Install the transaxle case.

1. Position the transaxle case in place.
2. Install the Shim Selection Set bolts.
5. Mount the Dial Indicator Gauge with Holding Fixture to the transaxle case.
6. Rotate the input shaft to seat the bearings.
7. Zero the Dial Indicator Gauge with Holding Fixture.
8. NOTE: The shaft must be lifted equally on both sides or it may bind on one side, resulting in an
incorrect reading.
Rotate the input shaft until the Dial Indicator Gauge returns to zero, then raise the input shaft and read
the end play.
• Take and record 3 readings within 0.10 mm (0.003 in) of each other. Use the formula below
to select the correct shim size.
Average the 3 readings Example

Reading A 0.019
Transaxle 4387
Reading B 0.014
Reading C +0.021
0.054 ÷ 3 = 0.018
Final Shim Size 0.018
9. NOTE: Do not use more than 2 shims.
From the Shim Selection Set, select the shim(s) that is closest to (or slightly thinner than) the final
shim size calculated in the previous step.
10. Remove the transaxle case, Shim Selection Set, bearing cup and input shaft.
11. Install the input shaft shim(s).
12. Install the input shaft bearing cup.
13. Install the funnel and the output shaft bearing cup.
14. Install the output shaft.
Transaxle 4388
16. NOTE: The gauge halves must be turned to eliminate any gap between them.
Install the Shim Selection Set.

18. Mount the Dial Indicator Gauge with Holding Fixture on the transaxle case.
19. Rotate the output shaft to seat the bearings.
20. Zero the Dial Indicator Gauge.
Transaxle 4389
21. NOTE: The shaft must be lifted equally on both sides or it may bind on one side, resulting in an
incorrect reading.
Rotate the output shaft until the Dial Indicator Gauge returns to zero, then raise the output shaft and
read the end play.
• Take and record 3 readings within 0.10 mm (0.003 in) of each other. Use the formula below
to select the correct shim size.
Average the 3 readings Example

Reading A 0.019
Reading B 0.014
Reading C +0.021
0.054 ÷ 3 = 0.018
Final Shim Size 0.018
2. NOTE: Do not use more than 2 shims.
From the Shim Selection Set, select the shim(s) that is closest to (or slightly thinner than) the final
shim size determined in the previous step.
23. Remove the transaxle case, Shim Selection Set, bearing cup and output shaft.
24. Install the shim.
25. Install the funnel and the output shaft bearing cup.
26. Install the differential.
Transaxle 4390
28. NOTE: The gauge halves must be turned to eliminate any gap between them.
Install the Shim Selection Set.

30. Using the Shim Selection Set, adjust gauge until the free play is removed. Turn gauge back together.
31. Insert the Differential Rotator through the transaxle case and engage the differential pinion shaft.
Transaxle 4391
32. Using the Differential Rotator and Shim Selector Set, adjust gauge until the differential rotation is
within specification.
33. Measure the gap in the Shim Selector Set.
34. NOTICE: Do not use more than 2 differential shims.
Add 0.15 mm (0.005 in) to the measurement to achieve the final clearance.
• Using the following chart, select the differential bearing shims that are closest to (or slightly
larger than) the final shim size.
Shim Thickness
0.10 mm (0.003 in)
0.15 mm (0.005 in)
0.20 mm (0.007 in)
0.25 mm (0.009 in)
0.30 mm (0.011 in)
0.35 mm (0.013 in)
0.40 mm (0.015 in)
0.45 mm (0.017 in)
0.50 mm (0.019 in)
0.55 mm (0.021 in)
0.60 mm (0.023 in)
0.65 mm (0.025 in)
0.70 mm (0.027 in)
0.75 mm (0.029 in)
0.80 mm (0.031 in)
Transaxle 4392
0.85 mm (0.033 in)

0.90 mm (0.035 in)
0.95 mm (0.037 in)
1.00 mm (0.039 in)
1.05 mm (0.041 in)
1.10 mm (0.043 in)
1.15 mm (0.045 in)
1.20 mm (0.047 in)
35. Remove the transaxle case, Shim Selection Set, differential and bearing cup.
36. Install the differential bearing cup shim(s) into the transaxle case.
37. Using the Differential Bearing Cup Installer and Handle, install the differential bearing cup into the
transaxle case.
38. Install the output shaft, the input shaft and the differential together.
39. Install the spring and the shift detent.
40. Shift the synchronizers into the 2nd and 4th gear positions.
Transaxle 4393
41. Install the main shift control shaft assembly, shift forks.
42. NOTE: Align the reverse idler shaft anchor bolt hole for installation of the bolt through the case.
Install the reverse idler gear and shift fork.
43. Install the shift control shaft and the shift gate.
44. NOTE: Make sure to align the shift gate at the bottom and the shift gate with the main shift control.
Install the shift gate bolt.
45. NOTE: Shift lever shaft uses a solid pin.
Install the shift lever shaft, shift fork selector lever and shift shaft pin.
Transaxle 4394
46. Install the magnet.
47. Position the 2nd and 4th gear synchronizers into neutral, then shift the 1st/2nd gear synchronizer into
neutral.
48. Install the oil funnel.
49. NOTE: The transaxle case must be installed within 4 minutes after applying silicone gasket and
sealant.
Apply a small bead of silicone gasket and sealant to the transaxle mating surface.
Install the transaxle case and the 2 transaxle case bolts.
• Make sure to align the shift lever to the shift lever shaft. Do not move the shaft outward to the
stop. The washer can slide off of the shaft into the case.
50. Install the shift detent ball, spring and bolt.

51. NOTE: Make sure that the shift rail guide bolt is in the groove of the shift rail.
NOTE: Do not shift the transaxle until the reverse idler shaft lock bolt and the shift rail guide bolt are
installed.
Transaxle 4395
Install the reverse idler shaft lock bolt and the shift rail guide bolt.
1. Install the reverse idler shaft lock bolt.

♦ Tighten the reverse idler shaft lock bolt to 22 Nm (16 lb-ft).
2. Install the shift rail guide bolt.
♦ Tighten the shift rail guide bolt to 12 Nm (106 lb-in).
52. Check the shift function.
53. Install the remaining 13 transaxle case bolts.

54. Install the primary and secondary 5th gears.
55. Install the spacer and the gear sleeve.
56. Install the 5th/6th shift fork and synchronizer assembly.
57. Install the gear spacer.
Transaxle 4396
58. Install the primary and secondary 6th gears.
59. NOTE: When the locknuts are tightened to specifications they will seat the bearings.
Install the 6th gear bearings onto the primary and secondary shafts.
60. Shift the 5th/6th gear shift fork to 5th.
61. NOTE: Do not reuse locknuts.
Install the new primary and secondary shaft locknuts.
1. Shifting into 5th/6th gears and using the Transmission Turning Torque Socket will keep the
primary shaft from turning.
2. Install the new primary and secondary shaft locknuts. Using a punch, stake the locknuts to the
shafts.
Transaxle 4397
62. NOTE: Shift 5th/6th into neutral.
Install a new 5th/6th shift fork roll pin.
63. NOTE: The case cover must be installed within 4 minutes after applying silicone gasket and sealant.
Apply a small bead of silicone gasket and sealant to the case and case cover mating surface.
64. Install the case cover and the 9 case cover bolts.
65. If removed, install the anchor bolt.

66. Install the clutch release fork and bearing.

1. Install the clutch release fork and diaphragm.
2. Install the clutch release bearing.
Transaxle 4398
67. Remove the transaxle from the Holding Fixture.
Transaxle 4399
Transaxle
Special Tool(s)
Powertrain Lift
Support Bar, Engine

303-F072 or equivalent

Material
Item Specification
CXG-1-C (Canada)
XT-4-QGL
TA-25
1. NOTE: Wipe off excess grease. The splines should have a thin film of grease only. Excess grease can
contaminate the clutch facing and affect clutch function.
Apply a very small amount of grease on the input shaft splines.
2. Secure the transaxle to a suitable transmission jack with a safety strap. Raise and position the
transaxle behind the engine.
3. Install the clutch housing-to-oil pan bolt.

Transaxle 4400
4. Install the 2 oil pan-to-clutch housing bolts.

5. Install the 4 lower transaxle-to-engine bolts.

6. Apply threadlock and sealer to the threads and install the 2 transmission lower mount nuts and bolt to
the transaxle. Do not tighten the fasteners at this time.
7. Position the clutch slave cylinder to the clutch release arm and install the bolts.
8. Install the clutch tube hydraulic line bracket bolts.

10. Place the subframe assembly on the Powertrain Lift and raise the subframe into the installed position.
Transaxle 4401
Transaxle 4402
Install the stabilizer bar links and nuts on the struts.
16. Install the 2 roll restrictor bracket bolts.

18. Attach the EPAS system wiring harness pin-type retainer to the subframe under the LH fender splash
shield.
19. Attach the 2 EPAS system wiring harness pin-type retainers to the subframe.
Transaxle 4403
21. Install the LH halfshaft and the intermediate shaft. For additional information, refer to Section 205-04
.
Transaxle 4404
27. Connect the reverse lamp switch electrical connector.
28. Connect the Output Shaft Speed (OSS) sensor electrical connector.
29. Fill the transaxle with clean gear oil. For additional information, refer to Transaxle Draining and
Filling in this section.
30. Install the splash shield and the 7 bolts.

interior can occur.
Transaxle 4405
32. Install the steering column shaft onto the steering gear and install a new bolt.
34. NOTE: If one or both of the mount studs were removed or came out, do not reinstall the old stud(s).
Install a new stud(s). Make sure they are properly seated in the case.
Tighten the transaxle rear support insulator nuts and bolt to specification.
35. Install the 3 upper transaxle-to-engine bolts.

36. Attach the wire harness to the transaxle.
38. Install the gearshift and shift cables onto the transaxle bracket and gearshift control assembly. Make
sure the cables are engaged in the shift bracket and fully installed on the gearshift control assembly.
Transaxle 4406
40. Install the Air Cleaner (ACL) assembly. For additional information, refer to Section 303-12A .
41. If the input shaft was replaced, use the scan tool to perform the Misfire Monitor Neutral Profile
42. Check the vehicle for normal operation.
Transaxle 4407
SECTION 308-06: Manual Transaxle/Transmission 2012 Fusion, MKZ, Fusion Hybrid, MKZ
External Controls Hybrid Workshop Manual

Gearshift cable grommet nuts 8 - 71
Gearshift lever nuts 23 17 -
Transaxle 4408
External Controls
The manual transaxle external controls consist of the following:
• Gearshift lever
• Gearshift lever knob and boot
• Gearshift cables
between the floor mounted gearshift lever and the manual transaxle gearshift control assembly is made
through 2 gearshift cables.
When the operator moves the floor mounted gearshift lever, that movement is transmitted through 2 gearshift
cables routed through the body to the transaxle. The 2 gearshift cables are attached to the transaxle at the
gearshift control assembly. The gearshift control assembly transfers the movement of the gearshift cables to
the shift rods and shift forks located inside the transaxle. Removal and installation of the gearshift cables
requires specific adjustments for correct shifting of the transaxle. For information regarding gearshift cable
adjustments, refer to Section 308-00 .

Gearshift Lever

1 7210 Gearshift lever assembly
2 - Gearshift lever nut (4 required)
3 7E395 Shift cable
4 7E395 Select cable
Removal
1. Remove the gearshift knob.
2. Open the storage compartment door.
3. Remove the floor console finish panel. Disconnect the electrical connectors.
4. Remove the LH floor console trim panel. For additional information, refer to Section 501-12 .
5. Disconnect the shift cable and the select cable from the gearshift lever.
Gearshift Lever 4410

6. NOTICE: Carefully disconnect the gearshift cables from the gearshift lever base. Do not
damage the gearshift cable retainers.
Disconnect the gearshift cables from the gearshift lever base.
7. Remove the 4 gearshift lever nuts.
8. Remove the gearshift lever assembly.
Installation
1. Position the gearshift lever assembly in the vehicle.
2. Install the 4 gearshift lever nuts.

3. NOTICE: Make sure the gearshift cables are fully seated into the gearshift lever base or damage
may occur.
Connect the gearshift cables to the gearshift lever base.

4. Connect the select cable and the shift cable to the gearshift lever.
5. Adjust the gearshift cables. For additional information, refer to Section 308-00 .
6. Install the LH floor console trim panel. For additional information, refer to Section 501-12 .
7. Install the floor console finish panel and connect the electrical connectors.
8. Close the storage compartment door.
9. Install the gearshift knob.


Gearshift Cables

1 7K391 Gearshift cable ends
2 7E395 Shift cable
4 - Gearshift cable grommet (part of 7E395)
5 W707142-S439 Gearshift cable grommet nuts
6 7E395 Shift cable
8 - Gearshift lever nut (4 required)
9 7210 Gearshift lever assembly
Removal
412-01 .
3. Disconnect the gearshift cables from the transaxle shift control lever.
Gearshift Cables 4414

4. NOTE: Carefully pry the retainer on the gearshift cables. Do not damage the gearshift cable retainers.
Disconnect the gearshift cs from the transaxle bracket.
6. Position the insulation blanket aside.
7. Remove the wiring harness from the studs.
8. Remove the 2 gearshift cable grommet nuts and detach the gearshift cables from the floor.
9. Disconnect the shift cable and select cable from the gearshift lever.
10. NOTICE: Carefully disconnect the gearshift cables from the gearshift lever base. Do not
damage the gearshift cable retainers.
Disconnect the gearshift cables from the gearshift lever base.

11. Pull the gearshift cables through the bulkhead into the interior.
Installation
1. NOTICE: When inserting the gearshift cables through the bulkhead, use care and do not
damage the heat shielding.
NOTE: When inserting the gearshift cables through the bulkhead, make sure the arrow on the
grommet is pointing upward.
Pull the gearshift cables through the bulkhead into the exterior.
2. Install the 2 gearshift cable grommet nuts and attach the gearshift cables to the floor.
3. Install the wiring harness onto the studs.
4. NOTICE: Make sure the gearshift cables are fully seated into the gearshift lever base or damage
may occur.
Connect the gearshift cables to the gearshift lever base.
5. Connect the select cable and the shift cable to the gearshift lever.

6. Position the insulation blanket into place.
8. NOTICE: Make sure the gearshift cables are fully seated into the transaxle bracket or damage
may occur.
NOTE: The gearshift cable ends and transaxle bracket slots are unique. They can only be fully seated
in the correct slot.
NOTE: The top cable will have id tape.
Connect the gearshift cables to the transaxle bracket.
9. Connect the gearshift cables to the transaxle shift control lever.
10. Adjust the gearshift cables. For additional information, refer to Section 308-00 .
11. Install the battery tray. For additional information, refer to Section 414-01 .
412-01 .


SECTION 308-07A: Four Wheel Drive (4WD) 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid
Systems Workshop Manual
Material

Capacity
Motorcraft SAE 75W-140 WSL-M2C192-A 530 ml
Synthetic Rear Axle Lubricant (18 oz) a
XY-75W140-QL (US);
CXY-75W140-1L (Canada)
Motorcraft SAE 80W-90 WSP-M2C197-A 1.15L
Premium Rear Axle Lubricant (2.43 pt) b
XY-80W90-QL (US);
a Power transfer unit (PTU)
b Rear differential unit (RDU)
4X4 control module nuts 9 80

Four Wheel Drive (4WD) Systems
The All-Wheel Drive (AWD) system consists of the following:
• Power Transfer Unit (PTU)

• Rear driveshaft
• AWD relay module
• Rear axle with coupling device
Torque from the engine is transferred through the transaxle to the PTU . This torque is transferred from the
driveshaft to the rear axle, which drives the rear halfshafts. The AWD system, also referred to as an Active
Torque Coupling (ATC) system, is always active and requires no driver input.
The AWD system continuously monitors vehicle conditions and automatically adjusts the torque distribution
between the front and rear wheels. During normal operation, most of the torque is delivered to the front
wheels. If wheel slip between the front and rear wheels is detected, or if the vehicle is under heavy
acceleration, the AWD system increases torque to the rear wheels to prevent or control wheel slip. When the
AWD system is functioning properly, there should be no perceived speed difference between the front and
rear axles when launching or driving the vehicle on any uniform surface. Traction should be similar to a part
time Four-Wheel Drive (4WD) system in 4H (4X4 HIGH), but have no binding in turns.
Serviceable components of the PTU are limited to the output shaft seal and flange, intermediate shaft seal and
deflector, and the PTU transaxle compression seal. No internal components are serviced. There should be no
need to remove the PTU cover. If any of the internal geared components, bearings, case cover or shafts are
worn or damaged, a new PTU must be installed.
Four Wheel Drive (4WD) Systems 4420

Four Wheel Drive (4WD) Systems
Special Tool(s)
Flex Probe Kit

105-R025D or equivalent


The vehicle is equipped with an All-Wheel Drive (AWD) system, also referred to as Active Torque Coupling
(ATC), that is always active and requires no driver input. The system has no Mode Select Switch (MSS).
Two transmissions are used with AWD . Vehicles with a 3.0L engine have the 6F35 transmission, controlled
by the PCM. Vehicles with the 3.5L engine use the Aisin AW21, which is controlled by a stand-alone
Transmission Control Module (TCM).
The system continuously monitors vehicle conditions and automatically adjusts the torque distribution
between the front and rear wheels. During normal operation, most of the torque is sent to the front wheels. If
wheel slip between the front and rear wheels is detected or if the vehicle is under heavy acceleration
(high-throttle position), the AWD system increases torque to the rear wheels to prevent or control wheel slip.
AWD faults may be indicated in the message center by the wrench lamp as well as the CHECK AWD
message.
The system consists of a Power Transfer Unit (PTU), 4X4 control module, rear axle and a solenoid actuated
ATC device. Based on the amount of current sent to the clutch, the module varies the torque sent to the rear
wheels by sending a duty cycle to the ATC device, located inside the rear axle. For concerns with the PTU ,
refer to Section 308-07B .
The 4X4 control module also provides the brake system with its current clutch duty cycle and determines
whether or not the brake system may take command of the clutch duty cycle.
NOTE: The ATC solenoid is not repairable. If a new component is required, the ATC solenoid and rear axle
are installed as an assembly. Refer to Section 205-02 .
The active, on-demand AWD system uses data from other systems as inputs to the 4X4 control module. The
4X4 control module uses the inputs to determine the appropriate amount of current to send to the ATC
solenoid that delivers the desired torque to the rear wheels. Specific inputs to the 4X4 control module are:
Four Wheel Drive (4WD) Systems 4421

• Accelerator pedal position via the High Speed Controller Area Network (HS-CAN)
• Transaxle range from the TCM or PCM via the HS-CAN
• Brake system status from the ABS module via the HS-CAN
• Wheel speed from all 4 wheels from the ABS module via the HS-CAN
4X4 control module outputs are:
• Solid-state clutch (Pulse-Width Modulation (PWM) signal) to the ATC solenoid

• Percent of torque transfer commanded signal to the ABS module via the HS-CAN
• Torque request available signal to the ABS module via the HS-CAN
Heat Protection Mode
During very extreme off-road operation, the AWD system utilizes a heat protection mode to protect the ATC
solenoid (part of rear axle) from damage. If the system detects an overheat condition, it enters a locked mode.
If the heat in the system continues to rise once in the locked mode, the 4X4 control module disables the ATC
solenoid. Allow the system to cool down at least 10 minutes with the ignition switch in the ON position.
2. Inspect for obvious signs of mechanical or electrical damage.
• Active Torque Coupling (ATC) solenoid (part of • Smart Junction Box (SJB)
rear axle) fuse(s):
• Power Transfer Unit (PTU) ♦ 11 (10A)
• Rear Drive Unit (RDU) ♦ 35 (10A)
• Halfshafts and CV joints • 4X4 control module
• Driveshaft and U-joints • Wiring harness
• Fluid leaks • Connector(s)
• Wheel/tire size and brand • Circuitry
• Matching tire size and brand
• Tire pressure
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
4. NOTE: Make sure to use the latest scan tool software release.
If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC).
5. NOTE: The Vehicle Communication Module (VCM) LED prove out confirms power and ground
from the DLC are provided to the VCM .
Heat Protection Mode 4422

If the scan tool does not communicate with the VCM :

• refer to Section 418-00 , No Power To The Scan Tool, to diagnose no power to the scan tool.

• verify the ignition is in the ON position.
• refer to Section 418-00 to diagnose no response from the PCM.

• If the scan tool responds with no communication for one or more modules, refer to Section
418-00 .
• If the network test passes, retrieve and record Continuous Memory Diagnostic Trouble Codes
(CMDTCs).
8. Clear the DTCs and carry out the self-test diagnostics for the 4X4 control module.
9. If the DTCs retrieved are related to the concern, go to the 4X4 Control Module DTC Chart. For all
other DTCs, refer to Section 419-10 .
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart .
DTC Chart
4X4 Control Module DTC Chart
DTC Description Action

B1317 Battery Voltage High GO to Pinpoint Test B .
B1318 Battery Voltage Low GO to Pinpoint Test B .
B1342 Electronic Control Unit (ECU) is CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is
Faulted retrieved again, INSTALL a new 4X4 control module. REFER
to 4X4 Control Module in this section.
B2900 Vehicle Identification Number (VIN) CHECK the PCM configuration. REFER to Section 418-01 .
Mismatch
P1635 Tire/Axle Out of Acceptable Range GO to Pinpoint Test F .
P1824 Four-Wheel Drive (4WD) Clutch GO to Pinpoint Test D .
Relay Circuit Failure
P1825 4WD Clutch Relay Open Circuit Check for a possible open fuse (B+) . GO to Pinpoint Test D .
U0100 Lost Communication with PCM or REFER to Section 418-00 to diagnose the lost communication
Transmission Control Module (TCM) with the PCM or TCM (3.5L only).
(3.5L only)
U0121 Lost Communication with Anti-lock REFER to Section 418-00 to diagnose the lost communication
Brake System (ABS) Control Module with the ABS control module.
U0155 Lost Communication with IC Control REFER to Section 418-00 to diagnose the lost communication
Module with the IC .
U0401 Invalid Data Received From PCM or REFER to Powertrain Control/Emissions Diagnosis (PC/ED)
TCM (3.5L only) manual to diagnose the accelerator position, engine coolant or
keep alive memory fault.
U0415 GO to Pinpoint Test C .

Invalid Data Received From

Anti-lock Brake System (ABS)
Control Module
U2050 No Application Present REPLACE the 4X4 control module. REFER to 4X4 Control
Module in this section. REPEAT the self-test.
U2051 One or More Calibration Files REPLACE the 4X4 control module. REFER to 4X4 Control
Missing/Corrupt Module in this section. REPEAT the self-test.
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: All-Wheel Drive (AWD) System Functional Test
Refer to Wiring Diagrams Cell 34 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), All Wheel Drive (AWD)
for schematic and connector information.
Normal Operation
The All-Wheel Drive (AWD) system continuously monitors vehicle conditions and automatically adjusts the
torque distribution between the front and rear wheels. During normal operation, most of the torque is
delivered to the front wheels. If wheel slip between the front and rear wheels is detected, or if the vehicle is
under heavy acceleration, the AWD system increases torque to the rear wheels to prevent or control wheel
slip.

• AWD system concern without on-demand or continuous DTCs
PINPOINT TEST A: ALL-WHEEL DRIVE (AWD) SYSTEM FUNCTIONAL TEST
WARNING: When directed to drive the vehicle as part of this test, drive the vehicle on a hard
surface in an area without traffic to prevent a crash. Failure to follow these instructions may result in
personal injury.
NOTE: Carry out a thorough inspection and verification as outlined before carrying out this pinpoint test.

A1 CHECK FOR WRENCH LIGHT
PROVE-OUT
Yes
• Turn the ignition to the ON position and GO to A2 .
observe the wrench light.
• Does the wrench light illuminate for 3 No
seconds and then turn OFF? REFER to Section 413-01 for further diagnosis of

the Instrument Cluster (IC).

A2 CHECK FOR ATC SOLENOID (PART OF
REAR AXLE) LOCK
Yes
• Drive the vehicle on a dry, hard surface in With the ignition switch in ON position, allow the
turns while applying the accelerator pedal. Active Torque Coupling (ATC) solenoid to cool
• Is driveline wind-up present in turns? down for at least 10 minutes and repeat the test.
CHECK for wind-up again. If no wind-up is
found, GO to A3 . If still present, GO to Pinpoint
Test E .
No
GO to A3 .
A3 CHECK FOR VALID ACCELERATOR
PEDAL POSITION MONITORING THE
ACCELERATOR PEDAL POSITION (AP) PID
Yes
• Enter the following diagnostic mode on the GO to A4 .
scan tool: DataLogger - 4X4 Control Module
. No
• Monitor the AP PID while pressing the REFER to the Powertrain Control/Emissions
accelerator pedal. Diagnosis (PC/ED) manual to diagnose the
• Does the accelerator pedal position match accelerator pedal position sensor concern.
the AP PID percent value?
A4 CHECK 4X4 CONTROL MODULE
WHEEL SPEED SENSOR PIDs
Yes
scan tool: DataLogger - 4X4 Control Module
. No
• While driving the vehicle at 48 km/h (30 GO to Pinpoint Test F .
mph), monitor the following wheel speed
sensor PIDs:
♦ Left Front Wheel Speed Sensor
(LF_WSPD)
♦ Left Rear Wheel Speed Sensor
(LR_WSPD)
♦ Right Front Wheel Speed Sensor
(RF_WSPD)
♦ Right Rear Wheel Speed Sensor
(RR_WSPD)
• Are all 4 wheel speeds within 2 km/h (1.2
mph) of each other?
A5 CHECK VEHICLE ACCELERATION IN A
STRAIGHT LINE
Yes
• Carry out 3 accelerations from 0-48 km/h GO to Pinpoint Test E .
(0-30 mph) in a straight line (one each with
low, medium and full accelerator pedal No
application). GO to A6 .
• Does the vehicle pulsate or shudder while
accelerating?
PINPOINT TEST A: ALL-WHEEL DRIVE (AWD) SYSTEM FUNCTIONAL TEST 4425

A6 CHECK VEHICLE TURNING ABILITY

Yes
• Drive the vehicle in a fully locked turn, on GO to Pinpoint Test E .
dry pavement, at 8 km/h (5 mph).
• Does the vehicle bind in the turn or resist No
turning? GO to A7 .
A7 CHECK FOR TORQUE AT REAR
WHEELS USING PWM OUTPUT CONTROL
COMMAND #1 (CLCH_SOL) ACTIVE
COMMAND
Yes
• Enter the following diagnostic mode on the END the active command. The concern cannot be
scan tool: DataLogger - 4X4 Control Module duplicated at this time. RETURN the vehicle to
. the customer.
• Using the scan tool, command CLCH_ SOL
to energize the ATC solenoid to a constant No
100% applied. END the active command. CHECK that the
• Drive the vehicle in a fully locked turn, on driveshaft rotates when the transaxle is in gear. If
dry pavement, at 8 km/h (5 mph). yes, GO to Pinpoint Test D . If no, CHECK the
• Does the vehicle bind in the turn or resist Power Transfer Unit (PTU). REFER to Section
turning? 308-07B .
npoint Test B: DTCs B1317 and B1318
Normal Operation
If the 4X4 control module observes an overpower or underpower voltage condition, DTCs are set and the 4X4
control module may not allow Four-Wheel Drive (4WD) operation.
• DTC B1317 Battery Voltage High - When the 4X4 control module detects battery voltage greater
than 16 volts for at least 10 seconds, this DTC is set.
• DTC B1318 Battery Voltage Low - When the 4X4 control module detects battery voltage less than 9
volts for at least 10 seconds, with the engine running at 1,500 rpm or greater, this DTC is set.

• Fuses
• Vehicle battery
• Charging system
• Wiring, terminals or connectors
• 4X4 control module
PINPOINT TEST B: DTCs B1317 AND B1318
NOTE: DTC B1or B1318 can be set if the vehicle has been recently jump started, the battery has been
recently charged or the battery has been discharged. The battery may become discharged due to excessive
load(s) on the charging system from aftermarket accessories or if the battery has been left unattended with the
accessories on.

NOTE: Carry out a thorough inspection and verification before proceeding with the pinpoint test. Refer to
Inspection and Verification in this section.

B1 RETRIEVE ALL CMDTCs IN ALL MODULES
Yes
• Enter the following diagnostic mode on the scan REFER to Section 414-00 for diagnosis of the
tool: Self Test - All CMDTCs . battery and charging system.
• Is DTC B1317 or B1318 present in more than
one module AND P0563, P0620, P0625, P0626 No
or P065B present in the PCM? GO to B2 .
B2 CHECK BATTERY CONDITION
Yes
• Refer to Section 414-01 and carry out the Battery If the battery passed the condition test but
- Condition Test. required a recharge, REFER to Section
• Does the battery pass the condition test? 414-00 to diagnose the charging system.
CLEAR all Continuous Memory Diagnostic
Trouble Codes (CMDTCs). TEST the system
for normal operation. If the battery passed the
condition test and did not require a recharge,
GO to B3 .
No
INSTALL a new battery. CLEAR all
CMDTCs . TEST the system for normal
operation.
&sp; B3 CHECK THE CHARGING SYSTEM
VOLTAGE
Yes
NOTE: Do not allow the engine rpm to increase GO to B4 .
above 2,000 rpm while performing this step or the
generator may self excite and result in default No
charging system output voltage. If engine rpm has REFER to Section 414-00 to diagnose the
gone above 2,000 rpm, shut the vehicle off and charging system. CLEAR all CMDTCs .
restart the engine before performing this step. TEST the system for normal operation.

• Measure the voltage of the battery.
♦ For DTC B1317, turn off all accessories
and run the engine at 1,500 rpm for a
minimum of 2 minutes.
♦ For DTC B1318, turn on headlights and
HVAC fan on high and run engine at
1,500 rpm for a minimum of 2 minutes.
PINPOINT TEST B: DTCs B1317 AND B1318 4427

• Is the battery voltage between 13-15.2 volts?

B4 CHECK FOR VOLTAGE BY MONITORING
THE MODULE SUPPLY VOLTAGE (VBAT_4X4)
PID
Yes
• Enter the following diagnostic mode on the scan If voltage is less than 9 volts, GO to B5 .
tool: DataLogger - 4X4 Control Module .
• With the engine running, monitor the battery If voltage is greater than 15.5 volts,
voltage VBAT_4X4 PID. INSTALL a new 4X4 control module.
• Is the battery voltage less than 9 or greater REFER to 4X4 Control Module in this
than 15.5 volts? section. CLEAR all CMDTCs . REPEAT the
self-test.
No
GO to B7
B5 CHECK CIRCUIT GD126 (BK/WH) FOR AN
OPEN
Yes
• Disconnect: 4X4 Control Module C3253 .
• Measure the resistance between 4X4 control No
module C3253-15, circuit GD126 (BK/WH), REPAIR the circuit. CLEAR all CMDTCs .
harness side and ground. REPEAT the self-test.
• Repeat this measurement while wiggling the
harness.

B6 CHECK POWER TO 4X4 CONTROL MODULE
Yes
• Ignition ON. GO to B7 .
• Measure the voltage between 4X4 control module
C3253-4, circuit CBP35 (YE/GY), harness side No
and ground; and between 4X4 control module VERIFY the Smart Junction Box (SJB)
C3253-5, circuit SBP11 (BU/RD), harness side fuse(s) 11 (10A) and 35 (10A) are OK. If
and ground. fuse(s) are OK, REPAIR the circuit in
question. If SJB fuse(s) are not OK, REFER
to the Wiring Diagrams manual to identify
possible causes of the circuit short. CLEAR
all CMDTCs . REPEAT the self-test.
PINPOINT TEST B: DTCs B1317 AND B1318 4428


B7 CHECK FOR CORRECT 4X4 CONTROL
MODULE OPERATION
Yes
• Disconnect the 4X4 control module. INSTALL a new 4X4 control module.
• Check the harness and component side connectors REFER to 4X4 Control Module in this
for: section. CLEAR the CMDTCs . REPEAT the
♦ corrosion. self-test.
♦ pushed-out/bent pins.
• Connect the 4X4 control module and make sure it No
seats correctly. The system is operating correctly at this time.
• Operate the system and determine if the concern The concern may have been caused by a loose
is still present. or corroded connector. CLEAR all CMDTCs
• Is the concern still present? . REPEAT the self-test.
Pinpoint Test C: DTC U0415
Normal Operation
The All-Wheel Drive (AWD) system uses data from other systems as inputs to the 4X4 control module. The
4X4 control module uses the inputs to determine the appropriate duty cycle to send to the Active Torque
Coupling (ATC) solenoid (part of rear axle) that delivers the desired torque to the rear wheels. Specific inputs
to the 4X4 control module are: accelerator pedal position output from the PCM, transmission range from the
PCM or Transmission Control Module (TCM) (3.5L only), brake system status and all 4 wheel speeds from
the ABS module. Communication between the 4X4 control module and other modules is obtained through the
High Speed Controller Area Network (HS-CAN). If the 4X4 control module loses communication with, or
receives invalid data from any of the necessary modules, DTCs are set and the 4X4 control module may not
allow Four-Wheel Drive (4WD) operation.
• DTC U0415 Invalid Data Received from Anti-lock Brake System (ABS) Control Module - When the
4X4 control module receives invalid HS-CAN bus data or invalid wheel speed(s) from the ABS
module for more than 5 seconds, this DTC is set.

• ABS module
PINPOINT TEST C: DTC U0415
personal injury.
NOTE: Carry out a thorough inspection and verification as outlined before carrying out this pinpoint st.

C1 CHECK FOR ABS MODULE DTCs
Yes

• Ignition ON. REFER to Section 206-09 for further diagnosis of the

• Carry out the ABS module self-test. ABS.
• Review the results of the ABS module
self-test. No
• Are any DTCs present? GO to C2 .
C2 CHECK WHEEL SPEED SENSORS
PIDs
Yes
• Enter the following diagnostic mode The system is operating correctly athis time. CLEAR the
on the scan tool: DataLogger - 4X4 DTCs. REPEAT the self-test.
Control Module .
• While driving the vehicle at 48 km/h No
(30 mph), monitor the following wheel INSPECT for proper tire size and tire inflation. If no
speed sensor PIDs: concerns with the tires are found, REFER to Section
♦ Left Front Wheel Speed 206-09 for further diagnosis of the ABS.
Sensor (LF_WSPD)
(LR_WSPD)
♦ Right Front Wheel Speed
Sensor (RF_WSPD)
♦ Right Rear Wheel Speed
Sensor (RR_WSPD)
• Do the 4 wheel speed sensors match
the speedometer and are they within
2 km/h (1.2 mph) of each other?
Pinpoint Test D: DTCs P1824 and P1825
Normal Operation
The All-Wheel Drive (AWD) system uses data from other systems as inputs to the 4X4 control module. The
4X4 control module uses the inputs to determine the appropriate duty cycle to send to the Active Torque
Coupling (ATC) solenoid (part of rear axle) that delivers the desired torque to the rear wheels. If the 4X4
control module loses communication with, or receives invalid data from any of the necessary modules, DTCs
are set and the 4X4 control module may not allow Four-Wheel Drive (4WD) operation.
• DTC P1824 4-Wheel Drive Clutch Relay Circuit Failure - When the 4X4 control module detects a
short to ground on the ATC solenoid feedback circuit, this DTC is set.
• DTC P1825 4-Wheel Drive Clutch Relay Open Circuit - When the 4X4 control module detects an
open or short to ground on the ATC solenoid command or feedback circuit for more than 2 seconds,
this DTC is set.

• Tire/axle out of range
• ATC solenoid (part of rear axle)
• Power Transfer Unit (PTU)
PINPOINT TEST C: DTC U0415 4430

PINPOINT TEST D: DTCs P1824 AND P1825

D1 CHECK FOR 4X4
CONTROL MODULE DTCs
Yes
• Ignition ON. For DTC P1824 or P1825, GO toa
• Carry out the 4X4 control href="SCS~us~en~file=SCS87A03.HTM~gen~ref.HTM#D2" >D2 .
module self-test.
• Are any DTCs received? For all other DTCs, REFER to the 4X4 Control Module DTC Chart in
this section.
No
GO to D2 .
D2 CHECK CIRCUITS
CCF21 (VT/WH) AND RCF21
(WH/VT) FOR A SHORT TO
GROUND WITH ATC
SOLENOID (PART OF REAR
AXLE) CONNECTED
Yes
• Disconnect: 4X4 Control
Module C3253 . No
• Measure the resistance GO to D3 .
between 4X4 control
module C3253-8, circuit
CCF21 (VT/WH),
harness side and ground;
and between 4X4 control
RCF21 (WH/VT),
harness side and ground.
• Are the resistances

greater than 10,000
ohms?
D3 CHECK CIRCUITS
(WH/VT) FOR A SHORT TO
GROUND WITH C3051
DISCONNECTED
PINPOINT TEST D: DTCs P1824 AND P1825 4431

• Disconnect: ATC Yes

Solenoid Jumper Harness GO to D4 .
C3051 .
• Measure the resistance No
between 4X4 control REPAIR the circuit(s) in question. CLEAR the DTCs. REPEAT the
module C3253-8, circuit self-test.
CCF21 (VT/WH),
harness side and ground;
and between 4X4 control
RCF21 (WH/VT),
• Are the resistances

greater than 10,000
ohms?
D4 CHECKING THE ATC
SOLENOID JUMPER
HARNESS
Yes
NOTICE: The Active REPAIR or INSTALL a new ATC solenoid jumper harness. CLEAR
Torque Coupling (ATC) the DTCs. REPEAT the self-test.
solenoid jumper harness
must be secured to No
prevent damage to the INSTALL a new rear axle assembly. REFER to Section 205-02 .
wiring. CLEAR the DTCs. REPEAT the self-test.
• Disconnect: ATC
Solenoid C3254 .
• Inspect the ATC solenoid
jumper harness for
damage.
• Is the ATC solenoid
jumper harness
damaged?
D5 CHECK CIRCUITS
(WH/VT) FOR AN OPEN
WITH ATC SOLENOID
CONNECTED

• Connect: ATC Solenoid Yes

C3254 and ATC Solenoid GO to D8 .
Jumper Harness C3051 .
• Measure the resistance No
between 4X4 control GO to D6 .
CCF21 (VT/WH),
harness side and 4X4
control module
C3253-16, circuit RCF21
(WH/VT), harness side.
• Is the resistance less

than 10 ohms?
D6 CHECK CIRCUITS
(WH/VT) FOR AN OPEN AT
C3051
Yes
• Disconnect: ATC GO to D7 .
Solenoid Jumper Harness
C3051 . No
• Measure the resistance REPAIR the circuit in question. CLEAR the DTCs. REPEAT the
between 4X4 control self-test.
CCF21 (VT/WH),
harness side and ATC
C3051-1, circuit CCF21
(VT/WH).
• Repeat this measurement

while wiggling the
harness.
• Measure the resistance
between 4X4 control

RCF21 (WH/VT),
harness side and ATC
(WH/VT), harness side.

while wiggling the
harness.
• Are the resistances less
than 5 ohms?
D7 CHECK THE ATC
SOLENOID CIRCUIT FOR
AN INTERNAL OPEN
Yes
NOTICE: The Active REPAIR or INSTALL a new ATC solenoid jumper harness. CLEAR
Torque Coupling (ATC) the DTCs. REPEAT the self-test.
must be secured to No
prevent damage to the INSTALL a new rear axle assembly. REFER to Section 205-02 .
wiring. CLEAR the DTCs. REPEAT the self-test.
• Disconnect: ATC
Solenoid C3254 .
• Measure the resistance
between ATC solenoid
C3254-1, circuit CCF21
(VT/WH), component
side, and ATC solenoid
(WH/VT), component
side.

while wiggling the
harness.


than 10 ohms?
D8 CHECK CIRCUIT GD126
(BK/WH) FOR AN OPEN
Yes
• Measure the resistance GO to D9 .
between 4X4 control
module C3253-15, circuit No
GD126 (BK/WH), REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.

while wiggling the
harness.
than 5 ohms?
D9 CHECK THE 4X4
CONTROL MODULE
POWER CIRCUITS
Yes
• Ignition ON. GO to D10 .
• Measure the voltage
between 4X4 control No
module C3253-4, circuit VERIFY the Smart Junction Box (SJB) fuse(s) 11 (10A) and 35
CBP35 (YE/GY), harness (10A) are OK. If fuse(s) are OK, REPAIR the circuit in question. If
side and ground; and SJB fuse(s) are not OK, REFER to the Wiring Diagrams manual to
between 4X4 control identify possible causes of the circuit short. CLEAR all Continuous
module C3253-5, circuit Memory Diagnostic Trouble Codes (CMDTCs). REPEAT the
SBP11 (BU/RD), harness self-test.
side and ground.
• Are the voltages greater

than 10 volts?
D10 CHECK FOR CORRECT
4X4 CONTROL MODULE
OPERATION

• Disconnect: 4X4 Control Yes

Module C3253 . INSTALL a new 4X4 control module. REFER to 4X4 Control
• Check the harness and Module in this section. CLEAR the DTCs. REPEAT the self-test.
component side
connectors for: No
♦ corrosion. The system is operating correctly at this time. The concern may have
♦ pushed-out/bent been caused by a loose or corroded connector. CLEAR the DTCs.
pins. REPEAT the self-test.
• Check the ATC solenoid
jumper harness between
the 4X4 control module
and the ATC solenoid,
located on the rear
subframe.
• Connect the 4X4 control
module and make sure it
seats correctly.
• Operate the system and
determine if the concern
is still present.
• Is the concern still
present?
Pinpoint Test E: Vehicle Binds in a Turn or Resists Turning/Pulsates or Shudders in a Straight Line
Normal Operation
torque distribution between the front and rear wheels. During normal operation, most of the torque is sent to
the front wheels. If wheel slip between the front and rear wheels is detected or the vehicle is under heavy
acceleration, the AWD system increases torque to the rear wheels.

• Rear axle
• Wheels/tires
• PCM
• ABS module
PINPOINT TEST E: VEHICLE BINDS IN A TURN OR RESISTS TURNING/PULSATES OR SHUDDERS IN A

STRAIGHT LINE

E1 CHECK FOR TORQUE AT THE REAR
WHEELS


• Disconnect: Active Torque Coupling (ATC) REFER to Section 205-00 for additional axle
Solenoid (part of rear axle) C3254 . diagnosis.
• Drive the vehicle in a straight line on dry
pavement. No
• Is a pulsation or shudder still present? GO to E2 .
E2 CHECK TO SEE IF THE ATC SOLENOID
IS BEING COMMANDED ON MONITORING
4WD CLUTCH PWM STATUS
(4WDCPWMST) PID
Yes
• Ignition OFF. GO to E3 . No
• Connect: ATC Solenoid C3254 . GO to Pinpoint Test F .
• Ignition ON.
• Enter the following diagnostic mode on the
scan tool: DataLogger - 4X4 Control
Module .
• Monitor the 4WDCPWMST PID.
• Drive the vehicle no faster than 8 km/h (5
mph) in tight turns on dry pavement while
monitoring the ATC solenoid duty cycle.
• Is the duty cycle greater than 20%?
E3 CHECK FOR THE CORRECT WHEEL
SPEEDS USING THE WHEEL SPEED
SENSORS PIDs
Yes
• Enter the following diagnostic mode on the GO to E4 .
scan tool: DataLogger - 4X4 Control
Module . No
• While driving the vehicle at 48 km/h (30 GO to Pinpoint Test F .
mph), monitor the following wheel speed
sensor PIDs:
(LF_WSPD)
(LR_WSPD)
(RF_WSPD)
(RR_WSPD)
• Are all 4 wheel speeds within 2 km/h (1.2
mph) of each other?
E4 CHECK FOR VALID ACCELERATOR
PEDAL POSITION MONITORING
ACCELERATOR PEDAL POSITION (AP) PID
Yes
• Key ON Engine OF(KOEO). GO to E5 .
scan tool: DataLogger - 4X4 Control No
Module . REFER to the Powertrain Control/Emissions
• Monitor AP PID while pressing/releasing Diagnosis (PC/ED) manual to diagnose the engine
the accelerator pedal. control system.
PINPOINT TEST E: VEHICLE BINDS IN A TURN OR RESISTS TURNING/PULSATES OR SHUDDERS

4437 IN
• Does the accelerator position match the

PID percent value?
E5 CHECK FOR CORRECT 4X4 CONTROL
MODULE OPERATION
Yes
• Disconnect the 4X4 control module. INSTALL a new 4X4 control module. REFER to
• Check the harness and component side 4X4 Control Module in this section. CLEAR the
connectors for: DTCs. REPEAT the self-test.
♦ corrosion.
♦ pushed-out/bent pins. No
• Check the ATC solenoid jumper harness The system is operating correctly at this time. The
between the 4X4 control module and the concern may have been caused by a loose or
ATC solenoid, located on the rear subframe. corroded connector. CLEAR the DTCs. REPEAT
• Connect the 4X4 control module and make the self-test.
sure it seats correctly.
• Operate the system and determine if the
concern is still present.
• Is the concern still present?
Pinpoint Test F: DTC P1635
Normal Operation
torque distribution between the front and rear wheels. During normal operation, most of the torque is sent to
the front wheels. If wheel slip between the front and rear wheels is detected or the vehicle is under heavy
acceleration, the AWD system increases torque to the rear wheels.
• DTC P1635 Tire/Axle Out of Acceptable Range - When the 4X4 control module detects inappropriate
mini spare or road wheels/tires (greater than 7% across the front and rear axle or 14% at one wheel)
installed, this DTC is set.

• Wheels/tires
• Wheel speed sensors
• ABS module
PINPOINT TEST F: DTC P1635
personal injury.

F1 CHECK THE RECENT TIRE USAGE

• Check with customer about recent tire Yes

usage or installation. INFORM the customer to only use tires of the type
• Has a tire been installed on the vehicle supplied with the vehicle. CLEAR the DTCs.
recently that was not originally REPEAT the self-test.
supplied with the vehicle?
No
GO to F2 .
F2 CHECK TIRE SIZE AND BRAND
Yes
• Check the tire size and the brand of tire. GO to F3 .
• Are all 4 tires the same size and brand?
No
INSTALL tires that are the same size and brand.
INFORM the customer to only use the same size tires
and brand. CLEAR the DTCs. REPEAT the self-test.
F3 CHECK TIRE AIR PRESSURES
Yes
• Check the air pressure in all 4 tires. GO to F4 .
• Are all 4 tires at the recommended air
pressure? No
ADJUST the tire air pressures. CLEAR the DTCs.
REPEAT the self-test. INFORM the customer to
maintain the correct tire air pressure.
F4 CHECK FOR CORRECT WHEEL
SPEEDS
Yes
• Connect the scan tool. GO to F5 .
• Enter the following diagnostic mode on
the scan tool: DataLogger - 4X4 Control No
Module . The ABS module is sending invalid wheel speed data
• While driving the vehicle at 48 km/h (30 to the 4X4 control module. REFER to Section 206-09
mph), monitor the following wheel speed for additional ABS diagnosis.
sensor PIDs:
(LF_WSPD)
(LR_WSPD)
(RF_WSPD)
(RR_WSPD)
• Are all 4 wheel speeds within 2 km/h
(1.2 mph) of each other?
F5 CHECK FOR CORRECT 4X4
CONTROL MODULE OPERATION
Yes
• Disconnect: 4X4 Control Module C3253 . INSTALL a new 4X4 control module. REFER to 4X4
• Check for: Control Module in this section. CLEAR the DTCs.
♦ corrosion. REPEAT the self-test.
♦ pushed-out pins.
• Connect the 4X4 control module and No
make sure it seats correctly. The system is operating correctly at this time. The
PINPOINT TEST F: DTC P1635 4439

• Operate the system and determine if the concern may have been caused by a loose or corroded
concern is still present. connector. CLEAR the DTCs. REPEAT the self-test.
PINPOINT TEST F: DTC P1635 4440

4X4 Control Module

1 - Electrical connector (part of 14A005)
2 W706840 4X4 control module nuts and washers (2 required)
3 7E453 4X4 control module and bracket assembly
1. From below the LH side instrument panel, disconnect the 4X4 control module harness connector.
2. Remove the two 4X4 control module nuts.

3. Remove the 4X4 control module and bracket.
4X4 Control Module 4441


SECTION 308-07B: Transfer Case - Power Transfer Unit 2012 Fusion, MKZ, Fusion Hybrid, MKZ
(PTU) Hybrid Workshop Manual
Material

Capacity
Metal Brake Parts Cleaner - -
PM-4-A or PM-4-B (US);
CPM-4 (Canada)
Motorcraft® MERCON® LV MERCON® LV -
XT-10-QLVC
Motorcraft® Premium WSS-M2C924-A -
XT-8-QAW (US);
Motorcraft® SAE 75W-140 WSL-M2C192-A 0.53L (18
Synthetic Rear Axle Lubricant and GL-5 oz)
XY-75W140-QL (US);
Silicone Brake Caliper Grease ESE-M1C171-A -
and Dielectric Compound
XG-3-A
Nm lb-ft lb-in
Driveshaft-to-output flange bolts 70 52 -
Filler plug 20 - 177
Pinion flange nut a - - -
Power Transfer Unit (PTU) support bracket bolts 48 35 -
PTU -to-transaxle bolts 90 66 -


SECTION 308-07B: Transfer Case - Power Transfer 2012 Fusion, MKZ, Fusion Hybrid, MKZ
Unit (PTU) Hybrid Workshop Manual
Power Transfer Unit (PTU)
The AWD system consists of the following:
• PTU
• Rear driveshaft
• Rear axle with coupling device
The PTU is a mechanical device attached to the transaxle. It supplies torque to the rear axle through the rear
driveshaft. The 4X4 control module is an electronic device which controls the rear axle coupling to apply the
torque generated from the PTU to the rear wheels when required.
Power Transfer Unit (PTU) 4445

SECTION 308-07B: Transfer Case - Power 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid
Transfer Unit (PTU) Workshop Manual
The Power Transfer Unit (PTU) is a gearbox that attaches to the transaxle. Vehicles equipped with the 3.0L
engine have the 6F35 transaxle and those with the 3.5L engine have the Aisin AW21 transaxle. The PTU
design is similar between the two. The RH intermediate shaft passes through the PTU and engages the
differential side gear as in normal Front Wheel Drive (FWD) applications. The PTU directs power to the rear
driveshaft through a helical gear spline coupled to the transaxle differential case, a helical gear drop (idler
gear) and hypoid/helical riear assembly and pinion set. The PTU is sealed from the transaxle and has its own
oil sump.
Serviceable components of the PTU are limited to the output shaft seal and flange, intermediate shaft seal and
deflector, cover seal and the PTU -transaxle compression seal. The internal components are not serviced. Do
not remove the cover of the PTU . If any of the geared components, bearings, case cover or internal shafts are
worn or damaged, a new PTU must be installed.
Heat Protection Mode
During very extreme off-road operation, the All-Wheel Drive (AWD) system utilizes a heat protection mode
to protect the Active Torque Coupling (ATC) solenoid (part of rear axle) from damage. If the system detects
an overheat condition, it enters a locked mode. If the heat in the system continues to rise once in the locked
mode, the 4X4 control module disables the ATC solenoid. Allow the system to cool down at least 10 minutes
with the ignition switch in the ON position.
For concerns with the 4X4 control module or ATC , refer to Section 308-07A .
2. Inspect for obvious signs of mechanical damage.
Mechanical
• Power Transfer Unit

(PTU)
• Halfshafts and CV
joints
• Driveshaft and
U-joints
• Wheel/tire size and
brand

• Matching tire size

and brand
• Tire pressure
4. If the cause is not visually evident, verify the symptom and GO to Symptom Chart - Power Transfer
Unit (PTU) .
Symptom Chart - Power Transfer Unit (PTU)
Symptom Chart - Power Transfer Unit (PTU)
Analysis of Leakage
NOTE: There are 2 different PTU configurations used depending on the transaxle. The repairs made for
leakage on these 2 different PTU s may vary depending upon the type and location of the leakage. The
specified tools called out in this section will allow seal replacement without causing damage to the PTU case
and drive gear.
NOTE: Inspection of the seal's mating journal should be performed every time a seal is replaced. The mating
part/journal should be replaced if it has any of the following conditions: Radial wear groove that can be felt by
running a finger nail across it where seal lip runs. Scratches, pitting, galling, nicks or other shaft damage
under or near where the seal lip runs. Discoloration or coked oil on the shaft where the seal lip runs. Shaft
corrosion under or near where the seal lip runs. Sharp edges or burrs on the shaft lead in chamfer. NEVER use
emery cloth on journal finishes, replace the part.
The PTU may leak different color fluids, red ATF or tan/brown/black gear lube. The PTU and transaxle seals
prevent these types of fluids from leaking. It is important to note which color of fluid is leaking to determine
the most appropriate service procedure. The residue of red ATF should be cleaned from the PTU to prevent a
inaccurate diagnosis of a red ATF leak following the repair.
PTU Leaks From the RH Side
Vehicles Equipped with Aisin AW21 Transaxle
NOTE: The intermediate shaft seal functions as a dust seal and is not a source of a red ATF leak.
If the leak is red ATF , this indicates the transaxle seal is leaking and needs to be replaced. For additional
information, refer to Section 307-01A .
If the leak is tan/brown/black gear lube, the PTU cover seal is leaking and needs to be replaced. This cover
seal is located on the PTU cover, behind the deflector. For additional information, refer to Cover Seal
procedure in this section.
Vehicles Equipped with 6F35 Transaxle

If the leak is red ATF , this indicates the intermediate shaft seal is leaking and needs to be replaced. For
additional information, refer to Intermediate Shaft Seal - 6F35 procedure in this section.
If the leak is tan/brown/black gear lube, the PTU cover seal is leaking and needs to be replaced. The cover
seal is located on the PTU cover, behind the deflector. For additional information, refer to Cover Seal
procedure in this section.
PTU Leaks From the LH Side
Vehicles Equipped with Aisin AW21 Transaxle
NOTE: The compression seal functions as a dust seal and is not the main source of the red ATF leak.
If the leak is tan/brown/black gear lube and not at the vent, check the non-serviceable PTU inboard seal for
leakage. If the PTU inboard seal is leaking, the PTU must be replaced. If the leak is from the vent, the PTU
may be overfilled. Determine if the red ATF has entered the PTU . If red ATF has entered the PTU , the
transaxle seal and PTU must be replaced. For additional information, refer to Section 307-01A and Power
Transfer Unit (PTU) in this section.
Vehicles Equipped with 6F35 Transaxle
information, refer to Section 307-01B .
If the leak is tan/brown/black gear lube, the PTU may be overfilled and leaking from the vent. If the PTU is
overfilled, adjust the level as necessary. If the leak is not at the vent, the non-serviceable PTU inboard seal is
leaking and the PTU must be replaced. For additional information, refer to Power Transfer Unit (PTU) in this
section.

Power Transfer Unit (PTU) Draining and Filling
Material
Item Specification
Motorcraft® SAE 75W-140 WSL-M2C192-A
Synthetic Rear Axle Lubricant and GL-5
XY-75W140-QL (US);
NOTICE: A new Power Transfer Unit (PTU) must be installed any time the PTU has been submerged
in water.
NOTE: The Power Transfer Unit (PTU) is not to be drained unless contamination is suspected. To drain the
PTU fluid, the PTU must be removed from the vehicle. The fluid that is drained may appear black and have a
pungent odor. Do not mistake this for contaminated fluid. For additional information, refer to Power Transfer
Unit (PTU) in the Removal portion of this section.
NOTE: Fill level checks are done in-vehicle only. Let the vehicle sit 10 minutes after the road test before
checking the fluid level.
100-02 .
2. Clean the area around the filler plug before removing.
3. Remove and discard the filler plug.
4. With the vehicle on a flat, level surface, fill the PTU with lubricant. The fluid must be even with the
bottom of the fill opening.
• Fluid capacity is 0.53L (18 oz).
5. Install a new filler plug.

Power Transfer Unit (PTU) Draining and Filling 4449

Power Transfer Unit (PTU) Draining and Filling 4450

Cover Seal
Special Tool(s)
Handle, Driver (32 in)

205-907

308-431td>
Installer, Shaft Bearing Cup

308-221 (T94P-7025-BH)
Remover, Halfshaft
205-241
Slide Hammer
100-01 (T50T-100-A)
Removal
NOTE: The Power Transfer Unit (PTU) may leak different color fluids, red Automatic Transmission Fluid
(ATF) and tan/brown/black gear lube for PTU fluid. The PTU seals prevent these types of fluids from leaking.
It is important to note which color fluid is leaking to determine the most appropriate service procedure. This
procedure will correct a tan/brown/black (gear lube) leak from the RH side of the PTU . For additional
information, refer to Analysis of Leakage in this section.
NOTE: This procedure is to be performed through the RH wheel opening. It is not necessary to remove the
exhaust components to complete this repair.
1. Remove the intermediate shaft seal deflector. For additional information, refer to Intermediate Shaft
Seal Deflector in this section.
2. NOTE: There is a bearing inside the PTU directly behind the cover seal. The bearing is not serviced.
Remove the cover seal using the Slide Hammer, the extension from the Halfshaft Remover and a
suitable seal puller inserted into the groove of the seal.
Installation
Cover Seal 4451

1. Assemble the Driver Handle, the Halfshaft Oil Seal Installer and the Shaft Bearing Cup Installer as
shown.
2. Using the Driver Handle, the Halfshaft Oil Seal Installer and the Shaft Bearing Cup Installer, install
the cover seal in the PTU .
3. Install the intermediate shaft seal deflector. For additional information, refer to Intermediate Shaft
Seal Deflector in this section.
4. Fill the PTU as necessary. For additional information, refer to Power Transfer Unit (PTU) Draining
and Filling in this section.
Cover Seal 4452

SECTION 308-07B: Transfer Case - Power

2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid
Transfer Unit (PTU)
Workshop Manual
>
Output Shaft Seal
Special Tool(s)
Holding Fixture, Drive Pinion Flange

205-126 (T78P-4851-A)
Installer, PTU Drive Gear Outer Oil Seal

308-430
Remover, Output Flange

307-523
Output Shaft Seal and Flange
Item Description
1 Collapsible spacer (part of 7275 kit)
2 Output shaft seal (part of 7275 kit)
3 Output pinion flange (part of 7275 kit)
4 Pinion flange nut (part of 7275 kit)
Removal
All vehicles
All vehicles except GTDI
2. Remove the 2 exhaust Y-pipe-to-muffler and tail pipe flange nuts.

• Discard the nuts and gasket.
3. NOTICE: The resonator must be supported to prevent damage to the flexible pipe.
Output Shaft Seal 4453

Using a length of mechanic's wire, support the resonator.
GTDI vehicles
4. Remove the 4 LH and RH exhaust flexible pipes-to-underbody catalytic converter nuts.

• Discard the nuts and gasket.
All vehicles
5. NOTE: Index-mark both the driveshaft flanges for installation.
Remove the 4 driveshaft-to- PTU output flange bolts. Disconnect the driveshaft from the PTU and
position it aside.
• Using mechanic's wire, support the driveshaft.
6. NOTE: Rotational torque of the PTU rear output shaft flange must be measured and recorded using a
Nm (lb-in) torque wrench for correct pinion bearing preload when reassembled. This will be the
torque-to-turn measurement.
Using a suitable torque wrench, measure and record the rotational torque of the PTU output shaft.
7. Using the Drive Pinion Flange Holding Fixture, hold the output pinion flange. Remove and discard
the pinion nut.
8. NOTE: Index-mark the output pinion flange to the pinion shaft.
Using the Output Flange Remover, remove the output pinion flange.
9. Remove and discard the output shaft seal.
10. Remove the bearing from the output shaft.
Output Shaft Seal and Flange 4454

11. Remove and discard the collapsible spacer.
Installation
All vehicles
1. Install the new collapsible spacer.
2. Install the bearing onto the output shaft.
3. Using the PTU Drive Gear Outer Oil Seal Installer, install the output shaft seal.
4. NOTE: Install the output pinion flange to engage the spline as previously marked.
Install the output pinion flange.
5. NOTICE: Refer to the rotational torque previously recorded with the Nm (lb-in) torque wrench.
Tighten the pinion nut in small increments until it is within 0.3 Nm (3 lb-in) of the reference
measurement. If 0.3 Nm (3 lb-in) is exceeded, then the collapsible spacer will be damaged and a
new collapsible spacer will be required.
Using the Drive Pinion Flange Holding Fixture to hold the output pinion flange, install and tighten the
new pinion flange nut.
6. Using the index mark, position the driveshaft and install the 4 driveshaft-to- PTU output flange bolts.
GTDI vehicles
7. Install the new LH and RH exhaust flexible pipe-to-underbody catalytic converter gaskets and nuts.
All vehicles except GTDI
8. Install the new exhaust Y-pipe-to-muffler and tail pipe flange gasket and nuts.
All vehicles

9. Fill the PTU as necessary. Refer to Power Transfer Unit (PTU) Draining and Filling .

Intermediate Shaft Seal Deflector
Special Tool(s)
Handle, Driver 32 in
205-907
Remover, Halfshaft
205-241
Remover, Transfer Case Bearing Cup

308-125 (T87P-7120-D)
Slide Hammer Master Set

100-D112 or equivalent
General Equipment
16 mm (5/8 in) washer (used with 308-125)
Material
Item Specification
Metal Brake Parts Cleaner -
PM-4-A or PM-4-B (US); CPM-4
(Canada)
XT-10-QLVC
Motorcraft® Premium Automatic
Transmission Fluid
(Canada) WSS-M2C924-A
Silicone Brake Caliper Grease and ESE-M1C171-A
Dielectric Compound
XG-3-A
Removal
NOTE: This procedure is to be performed through the RH wheel opening. It is not necessary to remove the
exhaust components to complete this repair.
Intermediate Shaft Seal Deflector 4457

2. NOTE: The following instruction will prevent the Transfer Case Bearing Cup Remover from opening
too far which would make removing the intermediate shaft seal deflector difficult.
Place a 16 mm (5/8 in) washer between the components of the Transfer Case Bearing Cup Remover
as shown.
NOTICE: Failure to utilize the recommended tools may result in serious damage to the Power Transfer
Unit (PTU).
3. Assemble the special tools as indicated in the following table and illustration:
Item Description
1 308-125
2 Extension from 205-241
3 100-D112 Slide Hammer Master Set
4. NOTE: Using a Slide Hammer Master Set eases the removal of the seal deflector.
Using the Bearing Cup Remover, the extension from the Halfshaft Remover and a suitable slide
hammer, remove the seal deflector.
• The seal deflector will have been damaged during removal. Remove all foreign material from
the PTU before continuing with the repair.
Installation
1. NOTICE: Do not overheat (melt) the seal deflector. Monitor the temperature of the deflector
with a suitable temperature measuring device, such as a digital temperature laser or infrared

thermometer, while heating. Do not allow the temperature to exceed 100°C (212°F).
Overheating will damage the deflector. If the deflector is damaged, a new deflector must be
used.
NOTE: Apply a small amount of silicone brake caliper grease and dielectric compound to the inner
lip of the deflecr where it installs on the tube inside the PTU before heating. This will ease the
installation of the deflector.
Position the deflector on the PTU Linkshaft Seal Dust Shield Installer using silicone brake caliper
grease and dielectric compound to retain it to the installer. Using a suitable heat gun, heat the
deflector to a minimum of 71°C (160°F) and a maximum of 93°C (200°F) by concentrating the heat
across the back of the installer while rotating the tool. Once the optimum temperature is achieved on
the tool, move the heat gun to the front of the tool and heat the inside of the deflector where it snaps
onto the PTU shaft until the temperature of the deflector is a minimum of 100°C (212°F).
• As an alternative method to heating the seal deflector, place the deflector in boiling water for
3 to 5 minutes. Dry off the deflector and install.
2. Using a 5-pound or larger dead blow hammer, install the seal deflector immediately after heating
using the PTU Linkshaft Seal Dust Shield Installer and Driver Handle.
3. Make sure the deflector is completely seated all the way around and there are no cracks on the face.
The deflector is correctly installed when the face of the deflector is recessed 3-5 mm (0.12-0.20 in)
into the pocket all the way around.
4. Fully install the intermediate and halfshaft assembly and the 2 bolts.

5. NOTE: A significant amount of residual fluid will collect between the seal and deflector during this
repair. This is a normal condition and should not be misinterpreted as a leak after the repair is
complete.
Using metal brake parts cleaner, thoroughly clean the deflector and intermediate shaft area of any
residual fluid that may have accumulated during the repair.
6. Fill the transaxle to the correct fluid level.

NOTE: 3.5L with Aisin AW21 transaxle shown, 3.0L with 6F35 transaxle similar.
Part
1 W500324 Power Transfer Unit (PTU)-to-support bracket bolts (2
required)
2 W500324 PTU support bracket-to-engine block bolts (3 required)
3 7A444 PTU support bracket
4 W500741 PTU -to-transaxle bolts (5 required)
5 7251 PTU
6 7087 Compression seal (vehicles equipped with Aisin AW21
transaxle)
All vehicles
100-02 .
2. Remove and discard the 4 front driveshaft-to-Power Transfer Unit (PTU) flange bolts.

3. Using a suitable pry bar as shown, separate the driveshaft flange from the PTU flange.
4. Remove the RH catalytic converter. For additional information, refer to Section 309-00 .
3.0L vehicles
All vehicles
6. Remove the 2 PTU -to-support bracket bolts, then remove the 3 PTU support bracket bolts and the
PTU support bracket.
7. Remove the 5 PTU -to-transaxle bolts.
8. Separate the PTU from the transaxle. Remove the PTU from the vehicle.
Vehicles equipped with Aisin AW21 transaxle
9. NOTICE: A new compression seal must be installed whenever the PTU is removed from the
vehicle. Failure to replace the compression seal may allow debris to enter the area around the
transaxle seal and cause the transaxle seal to fail.
Using a suitable tool, remove the compression seal and discard.


Intermediate Shaft Seal - 6F35
Special Tool(s)
Remover, PTO Driven Gear Oil Seal

308-428
Slide Hammer
100-001 (T50T-100-A)
1. NOTE: Red Automatic Transmission Fluid (ATF) leaking from the RH side of the Power Transfer
Unit (PTU) indicates a ntermediate shaft seal. For additional information, refer to Analysis of
Leakage in this section.
Remove the PTU . For additional information, refer to Power Transfer Unit (PTU) in the section.
2. Using the PTO Driven Gear Oil Seal Remover and Slide Hammer, remove the intermediate shaft seal.
Intermediate Shaft Seal - 6F35 4464

Material
Item Specification
XT-10-QLVC
Motorcraft® Premium WSS-M2C924-A
XT-8-QAW (US);
Motorcraft® SAE 75W-140 WSL-M2C192-A
Synthetic Rear Axle Lubricant and GL-5
XY-75W140-QL (US);
NOTE: 3.5L with Aisin AW21 transaxle shown, 3.0L with 6F35 transaxle similar.
Part
1 7087 Compression seal
(vehicles with
Aisin AW21
transaxle)

2 W500324 Power Transfer

Unit
(PTU)-to-support
bracket bolts (2
required)
3 W500324 PTU support
bracket-to-engine
block bolts (3
required)
4 7A444 PTU support
bracket
5 W500741 PTU -to-transaxle
bolts (5 required)
6 7251 PTU
Vehicles equipped with Aisin AW21 transaxle
1. NOTICE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is
removed from the vehicle. Failure to replace the compression seal may allow debris to enter the
area around the transaxle seal and cause the transaxle seal to fail.
Using a suitable tool, install the new compression seal.
All vehicles
2. Position the Power Transfer Unit (PTU) to the transaxle. Install the 5 PTU -to-transaxle bolts.
3. Position the PTU support bracket into place and install the 5 PTU support bracket bolts.
1. Tighten the bolts to the PTU to 48 Nm (35 lb-ft).
2. Tighten the bolts to the engine to 48 Nm (35 lb-ft).

4. Position the driveshaft and install 4 new driveshaft-to- PTU flange bolts.
3.0L vehicles
All vehicles
6. Install the RH catalytic converter. For additional information, refer to Section 309-00 .
7. Fill the transaxle and/or PTU as necessary.

Intermediate Shaft Seal - 6F35
Special Tool(s)
Handle
205-153 (T80T-4000-W)
Installer, PTO Driven Gear Oil Seal

308-429
1. Using the Handle and PTO Driven Gear Oil Seal Installer, install the intermediate shaft seal.
2. Install the Power Transfer Unit (PTU). For additional information, refer to Power Transfer Unit
(PTU) in this section.


SECTION 309-00: Exhaust System
Manual

Bracket-to-LH catalytic converter bolts (3.5L) 20 - 177
Bracket-to-RH catalytic converter bolts (3.5L) 20 - 177
Catalytic converter manifold bracket nuts and bolts (2.5L, 3.0L) 20 - 177
Catalytic converter manifold nuts (2.5L) a - - -
Catalytic converter manifold shield bolts (2.5L, 3.0L) 10 - 89
Catalytic converter manifold shield bracket bolts (2.5L) 20 - 177
Catalytic converter manifold studs (2.5L) 17 - 150
Catalytic converter support bracket-to-engine block nuts (3.5L) 40 30 -
Catalytic converter support bracket-to-transmission bolts (3.5L) 48 35 -
Catalytic converter-to-exhaust flexible pipe nuts (2.5L) 40 30 -
Exhaust flexible pipe-to-catalytic converter nuts (2.5L, 3.0L) 40 30 -
Exhaust manifold nuts (2.5L) 40 30 -
Exhaust manifold studs (2.5L) 25 18 -
Exhaust Y-pipe-to-LH catalytic converter nut (3.5L) 40 30 -
Exhaust Y-pipe-to-RH catalytic converter nut (3.5L) 40 30 -
Exhaust Y-pipe-to-resonator nuts (3.5L) 40 30 -
LH catalytic converter heat shield bolt (3.5L) 10 - 89
LH catalytic converter manifold bracket bolts (3.0L) 20 - 177
LH catalytic converter manifold nuts (3.0L) a - - -
LH catalytic converter manifold shield bolts "top" align="center">10 - 89
LH catalytic converter manifold shield bracket bolts (3.0L) 20 - 177
LH catalytic converter manifold studs (3.0L) 11 - 97
LH catalytic converter-to-exhaust flexible pipe nuts (3.0L) 40 30 -
LH catalytic converter-to-exhaust manifold nuts (3.5L) 40 30 -
LH catalytic converter-to-exhaust manifold studs (3.5L) 25 18 -
Power steering gear shield bolts 15 - 133
RH catalytic converter heat shield bolt (3.5L) 10 - 89
RH catalytic converter manifold shield bracket bolt (3.0L) 20 - 177
RH catalytic converter manifold shield bracket nuts (3.0L) 20 177
RH catalytic converter-to-exhaust flexible pipe bolts (3.0L) 40 30 -
RH catalytic converter-to-exhaust manifold nuts (3.5L) 40 30 -
RH catalytic converter-to-exhaust manifold studs (3.5L) 25 18 -
RH catalytic converter-to-manifold nuts (3.0L) 40 30 -
RH catalytic converter-to-manifold studs (3.0L) 25 18 -
Roll restrictor bolt (3.0L, 3.5L) 90 66 -

Torca® clamp 47 35 -
U-bolt nuts (2.5L) 30 22 -
Worm gear clamp 7 - 62
&nb


Manual
Exhaust System
The 2.5L exhaust system consists of:
• a one-piece catalytic converter manifold (hybrid only).

• an exhaust manifold (except hybrid).
• an exhaust flexible pipe.
• an underbody catalytic converter.
• a Catalyst Monitor Sensor (CMS) mounted to the underbody catalytic converter.
• a production muffler and tail pipe assembly.
• isolators installed on the body and muffler hangers.
• a one-piece catalytic converter manifold.

• a RH exhaust manifold-mounted catalytic converter.
• an exhaust flexible pipe.
• an underbody catalytic converter.
• two exhaust manifold-mounted catalytic converters.

• an exhaust Y-pipe.
• a resonator and flex assembly.
The exhaust system provides an exit for exhaust gases and reduces engine noise by passing exhaust gases
through the catalytic converters, a muffler assembly and resonator. Rubber exhaust hanger isolators attach the
exhaust system to the hangers welded on the body.
Catalytic Converter
The catalytic converter plays a major role in the emission control system. The catalytic converter operates as a
gas reactor. Its catalytic function is to speed the heat-producing chemical reaction of components in the
exhaust gases in order to reduce air pollutants.
The catalyst material inside the catalytic converter consists of a ceramic substrate.
The catalytic converter is designed to provide a long life. No maintenance is necessary for the catalytic
converter.
Precautions
NOTICE: Do not use leaded fuel in a vehicle equipped with a catalytic converter. In a vehicle that is
continually misfueled, the lead in the fuel will be deposited in the catalytic converter and completely
blanket the catalyst. Lead reacts with platinum to "poison" the catalyst. Continuous use of leaded fuel
Exhaust System 4471

can destroy the catalyst and render the catalytic converter useless. The addition of lead to the catalytic
converter can also solidify the catalyst, causing excessive back pressure in the exhaust system and
possibly causing engine damage.
NOTICE: Extremely high temperatures of 1,100°C (2,012°F) or above due to misfiring or an over-rich
fuel/air mixture will cause the ceramic substrate to sinter or burn, destroying the catalytic converter.
Do not continue to operate the vehicle if the engine is misfiring, there is a power loss or other unusual
operating conditions, such as engine overheating and backfiring.
Some exhaust fasteners must be discarded and new ones installed as indicated in the procedures. Also, any
damaged or heavily corroded fasteners should be discarded and new ones installed. Some exhaust fasteners
are of a prevailing torque design. Use only new fasteners with the same part number as the original. Torque
values must be used as specified during reassembly to make sure of correct retention of exhaust components.
Sound Insulators and Shields
Sound insulators and shields, attached to the underbody, protect the vehicle from exhaust system heat and
should be inspected at regular intervals to make sure they are not dented or out of position. If a sound
insulator and shield is damaged or shows evidence of deterioration, install a new insulator and shield. The
sound insulators and shields for the muffler, muffler pipe, resonator and catalytic converter pipe are installed
separately.
Exhaust System 4472


Manual
Exhaust System
2. Visually inspect the components of the exhaust system and related controls that may affect exhaust
gas quality or loss of power.
3. Visually inspect for obvious signs of mechanical damage. Refer to the following chart.
Mechanical
• Exhaust pipe pinched or crushed

• Damaged muffler
• Broken or damaged exhaust hanger brackets or
isolators
• Damaged catalytic converter
• Cracked exhaust manifold
• Loose or damaged heat shields
4. Verify that the exhaust system is installed correctly, with clamps correctly located and tightened to
specification.
5. If the fault is not visually evident, determine the symptom. GO to Symptom Chart - Exhaust System
or GO to Symptom Chart - NVH .
Symptom Chart - Exhaust System
Symptom Chart - Exhaust System
Symptom Chart - NVH
Symptom Chart - NVH

Exhaust System 4473

• Rattle, squeaks or buzz type noise - from the bottom of the vehicle
• Loose or damaged heat shield
• INSPECT the exhaust system for loose or missing heat shields or foreign material trapped between
the heat shields and the exhaust system components. If any heat shields are loose, INSTALL worm
gear clamp 7L5Z-5A231-AA and tighten to 7 Nm (62 lb-in). If the heat shields are missing,
INSTALL new heat shields or exhaust system components as necessary. If a rattle, noise or buzz
condition persists, INSTALL a new heat shield or component as necessary. TEST the system for
normal operation after the repair.
• Loose or damaged exhaust isolators
• VERIFY that the exhaust isolators are correctly installed. INSPECT the exhaust isolators for wear or
damage. INSTALL new isolators as necessary. TEST the system for normal operation after the repair.
• Damaged exhaust isolator hanger bracket
• INSPECT the exhaust system components for damage or broken hangers. INSTALL new components
as necessary. CHECK for loose or damaged exhaust hanger brackets. INSTALL new components as
necessary. TEST the system for normal operation after the repair.
• Loose or damaged catalytic converter or muffler
• Exhaust grounded to chassis
• INSPECT for signs of exhaust components-to-body contact. If necessary, CARRY OUT the Exhaust
System Alignment in this section.
• Drone or clunk type noise - from the bottom of the vehicle
• Loose or damaged exhaust isolators
• INSPECT the exhaust isolators for wear or damage. INSTALL new isolators as necessary. TEST the
system for normal operation after the repair.
• Exhaust grounded to chassis
• INSPECT for signs of exhaust components-to-body contact. If necessary, CARRY OUT the Exhaust
System Alignment in this section.
• Whistles, boom, hum or ticking type noise - noise tends to change as the engine warms. The noises
are often accompanied by exhaust fumes
• Exhaust system leak
• INSPECT the entire exhaust system for leaks. CHECK for punctures, loose or damaged
clamps/fasteners, gaskets, sensors or broken welds. EXAMINE the chassis for grayish-white or black
exhaust soot, which indicates exhaust leakage at that point. To magnify a small leak, have an assistant
hold a rag over the tail pipe outlet while listening for a leak. REPAIR or INSTALL new components
Exhaust System 4474

as necessary. TEST the system for normal operation after the repair.
• Catalytic converter
• MOVE the exhaust system to simulate the bouncing action of the vehicle, checking for
exhaust-to-body contact while moving the exhaust system. Using a rubber mallet, TAP on the exhaust
components to duplicate the noise concern. Lightly TAP on the muffler and the catalytic converter.
DETERMINE if there are loose or broken baffles in the muffler, or a loose or broken element in the
catalytic converter. REPAIR or INSTALL new components as necessary. TEST the system for
• Exhaust muffler/resonator drain hole enlarged due to corrosion
• CONFIRM the drain holes are the noise source. INSTALL new components as necessary. TEST the
• Hissing or rushing noise - high frequency sound. Vehicle performance is unaffected
♦ Exhaust system. Exhaust flow through pipes
• CHECK the exhaust system for leaks. Using a rubber mallet, TAP on the exhaust components to
duplicate the noise concern. Lightly TAP on the muffler and the catalytic converter. DETERMINE if
there are loose or broken baffles in the muffler, or a loose or broken element in the catalytic converter.
REPAIR or INSTALL new components as necessary. TEST the system for normal operation after the
repair.
• Pinging noise - occurs when exhaust system is hot, engine turned off
• Catalytic converter/exhaust system
• Cool down pinging is a result of the exhaust system expanding and contracting during heating and
cooling. This is a normal condition.
• Vibration - occurs at idle and at low speeds. Also accompanied by a clunk or buzz type noise
• Loose or damaged exhaust isolator
• INSPECT the exhaust isolators for wear or damage. INSTALL new isolators as necessary. TEST the
• Loose or damaged exhaust isolator hanger brackets
• INSPECT the exhaust isolator hanger brackets for wear or damage. INSTALL or REPAIR as
• Exhaust system grounded to chassis
• CARRY OUT the Exhaust System Alignment in this section.
• Engine drumming noise - normally accompanied by vibration
• Damaged or misaligned exhaust system
• INSPECT the exhaust system for loose or damaged fasteners, Torca® clamps or isolators. CARRY
Exhaust System 4475

OUT the Exhaust System Alignment in this section.
• Sputter type noise - noise worse when cold, lessens or disappears when the vehicle is at operating
temperature
• Damaged or worn exhaust system
• INSPECT the exhaust system for leaks or damage. REPAIR as necessary. TEST the system for
• Thumping noise - from the bottom of the vehicle, worse at acceleration
• Misaligned exhaust system
• CHECK the exhaust system to chassis clearance. CHECK the exhaust system isolators for damage.
REPAIR as necessary. TEST the system for normal operation after the repair.
• Loose or damaged body shield
• CHECK the body shield for damaged, loose or missing fasteners. REPAIR or REPLACE as
• Engine vibration - is felt with increases and decreases in engine rpm
• Strain on exhaust system isolators
• CARRY OUT the Exhaust System Alignment in this section. REPAIR as necessary. TEST the system
for normal operation after the repair.
• Drumming noise - occurs inside the vehicle during idle or high idle, hot or cold. Very low-frequency
drumming is very rpm dependent
• Exhaust system vibration excites the body resonances inducing interior noise
• GO to Pinpoint Test A .
Pinpoint Test
PINPOINT TEST A: DRUMMING NOISE

A1 CHECK THE EXHAUST SYSTEM
Yes
• Start the engine. REFER to Exhaust System
• Increase the engine rpm until the noise is the loudest. Note the Alignment in this section. TEST
engine rpm. the system for normal operation.
• Ignition OFF.
• Add approximately 9 kg (20 lb) of weight to the exhaust No
system.st place the weight at the tail pipe and test, then at the CONDUCT a diagnosis on other
PINPOINT TEST A: DRUMMING NOISE 4476

front pipe. suspect systems. REFER to

Section 100-04 .

• Increase the engine rpm and listen for the drumming noise.
Note the engine rpm if the noise occurs.
• Ignition OFF.
• Remove the weight from the exhaust system.
• Is the noise/vibration reduced or eliminated, or does the
noise/vibration occur at a different rpm?
PINPOINT TEST A: DRUMMING NOISE 4477


Manual
Exhaust System Alignment
100-02 .
2. Loosen all fasteners joining the exhaust system components.
3. Beginning at the front of the vehicle, align the exhaust system to establish the maximum clearance.
Make sure all fit pipes are pushed all the way into the preceding pipe and the notches are correctly
lined up with the tabs.
4. Beginning at the front of the vehicle, tighten all fasteners and clamps to specification. For additional
information, refer to Specifications in this section.
5. Start the engine and check the exhaust system for leaks.
Exhaust System Alignment 4478


Manual
Torca® Clamp
1. Remove the nut from the Torca® clamp.
2. Grind the spot weld from the Torca® clamp and remove the clamp.
3. Clean the uneven surface area and position a Torca® clamp.
4. NOTE: Make sure the clamp position is no more than 27.5 mm (1.08 in) or less than 25.5 mm (1 in)
from the inlet of the resonator pipe.
Make sure the back of the slot is covered by the clamp and the button is fully seated inside the notch.
5. NOTE: Do not tighten the clamp until the exhaust system has been aligned.
Tighten the Torca® clamp.
Torca® Clamp 4479

Torca® Clamp 4480


Manual
REMOVAL AND
INSTALLATION
Exhaust System - Exploded View
2.5L Hybrid
Part
1 W704474 Catalytic converter manifold stud (7 required)
2 5K282 Catalytic converter manifold shield
3 W503921 Catalytic converter manifold shield bolt (6 required)
4 14A464 Heated Oxygen Sensor (HO2S) electrical connector
5 14A464 Catalyst Monitor Sensor (CMS) electrical connector
6 5K291 Catalytic converter manifold shield bracket
7 W500021 Catalytic converter manifold shield bracket bolt (2
required)
8 W708176 Catalytic converter manifold nut (7 required)
9 9448 Catalytic converter manifold gasket
10 - Catalytic converter manifold bracket
11 5G236 Catalytic converter manifold
12 9451 Gasket
Exhaust System - Exploded View 4481

13 5G203 Exhaust flexible pipe

14 W520414 Catalytierter-to-exhaust flexible pipe nut (2 required)
15 W520414 Exhaust flexible pipe-to-catalytic converter nut (2
required)
16 9451 Gasket
17 5E212 Catalytic converter
18 5221 Torca® clamp
19 5F262 Muffler and tail pipe isolator (4 required)
20 5C257 Muffler and tail pipe
2.5L
Part
1 9N454 Catalytic converter manifold shield
2 W503921 Catalytic converter manifold shield bolt (4 required)
3 9430 Exhaust manifold
4 W711133 Exhaust manifold stud (2 required)
5 9451 Gasket
6 W520414 Exhaust manifold nut (2 required)
7 N802137 U-bolt
2.5L Hybrid 4482

9 W520414 U-bolt nut (2 required)

10 5K222 Catalytic converter manifold braket
14 9451 Gasket
required)
16 5C257 Muffler and tail pipe
3.0L Front Wheel Drive (FWD) (View 1 of 3)

1 W503921 LH catalytic converter manifold shield
bolt (4 required)
2 5K282 LH catalytic converter manifold shield
3 14A464 Heated Oxygen Sensor (HO2S)
electrical connector
4 9448 LH catalytic converter manifold gasket
5 W701732 LH catalytic converter manifold stud (6
required)
6 W711132 LH catalytic converter manifold bracket
bolt (2 required)
2.5L 4483
7 5K223 LH catalytic converter manifold bracket

8 5G232 LH catalytic converter manifold
9 14A464 Catalyst Monitor Sensor (CMS)
10 5K292 LH catalytic converter manifold shield
bracket
11 W500021 LH catalytic converter manifold shield
bracket bolt (2 required)
12 W701706 LH catalytic converter manifold nut (6
required)
13 W503921 RH catalytic converter manifold shield
bolt (5 required)
14 5K282 RH catalytic converter manifold shield
bracket nut (2 required)
bracket bolt
17 5K281 RH catalytic converter manifold shield
bracket
18 W520414 RH catalytic converter-to-manifold nut
(3 required)
19 5G236 RH catalytic converter manifold
20 5K291 RH catalytic converter manifold bracket
21 5F263 RH catalytic converter manifold gasket
22 W711133 RH catalytic converter-to-manifold stud
(3 required)
23 9428 RH exhaust manifold
24 5F262 Muffler and tail pipe isolator (5
required)
25 5G213 Muffler and tail pipe
3.0L, 3.5L (View 2 of 3)

1 W711575 Roll restrictor bolt
3.0L Front Wheel Drive (FWD) (View 1 of 3) 4484

3.0L All-Wheel Drive (AWD) (View 3 of 3)
Part
1 W713002 RH catalytic converter-to-exhaust flexible pipe bolt (2
required)
2 9451 Gasket
3 W520414 LH catalytic converter-to-exhaust flexible pipe nut (2
required)
4 5E241 Gasket
required)
7 9451 Gasket
11 5G213 Muffler and til pipe
3.0L All-Wheel Drive (AWD) (View 3 of 3) 4485

3.5L (View 1 of 3)
NOTE: Front Wheel Drive (FWD) shown, All-Wheel Drive (AWD) similar.

1 14A464 Catalyst Monitor Sensor (CMS)
2 - Catalytic converter support
bracket-to-transmission bolts (2
required)
3 W520414 LH catalytic converter-to-exhaust
manifold nut (4 required)
4 5F263 Gasket
5 W500222 Bracket-to-LH catalytic converter bolt
(2 required)
6 5E213 LH catalytic converter
7 9451 Gasket
8 W520414 Exhaust Y-pipe-to-LH catalytic
converter nut (2 required)
9 W520414 Exhaust Y-pipe-to-resonator nut (2
required)
10 5G274 Exhaust Y-pipe
11 5H292 Resonator
12 5G213 Muffler and tail pipe
13 9451 Gasket
14 W712458 LH catalytic converter-to-exhaust
manifold stud (4 required)
LH catalytic converter heat shield bolt
15 W500211
(3 required)
3.5L (View 1 of 3) 4486

3.5L (View 2 of 3)
NOTE: Front Wheel Drive (FWD) shown, All-Wheel Drive (AWD) similar.

16 14A464 RH CMS electrical connector
17 W710512/ Catalytic converter support bracket-to-engine block
W520414 nut (2 required)
18 W500222 Bracket-to-RH catalytic converter bolt (2 required)
19 W520414 RH catalytic converter-to-exhaust manifold nut (4
required)
20 5F263 Gasket
21 5E211 RH catalytic converter
22 W520414 Exhaust Y-pipe-to-RH catalytic converter nut (2
required)
25 W712458 RH catalytic converter-to-exhaust manifold stud (4
required)
26 W500211 H catalytic converter heat shield bolt (3 required)
27 - Gasket
3.5L (View 2 of 3) 4487

3.5L (View 3 of 3)

28 W500210 Power steering gear shield bolt (2 required)
29 - Power steering gear shield
1. For additional information, refer to the procedures in this section.
3.5L (View 3 of 3) 4488


Manual
REMOVAL AND
INSTALLATION
Catalytic Converter - Manifold, Hybrid
Removal
1. NOTE: Always install new fasteners and gaskets as indicated. Clean flange faces prior to new gasket
installation to make sure of proper sealing.
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .
2. Disconnect the Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS) electrical
connectors.
3. Remove the 2 catalytic converter manifold-to-exhaust flexible pipe nuts.

• Discard the gasket and the 2 nuts.
4. Remove the 6 catalytic converter manifold shield bolts and the heat shield.
5. Remove the 2 catalytic converter manifold shield bracket bolts and the bracket.
6. Loosen the 2 catalytic converter manifold bracket bolts.
7. Remove the 7 catalytic converter manifold nuts and remove the converter from the vehicle.
• Discard the 7 nuts and the gasket.
8. Remove and discard the 7 catalytic converter manifold studs.
9. Clean and inspect the catalytic converter manifold. For additional information, refer to Section 303-00
.
Installation
1. Install the 7 new catalytic converter manifold studs.

2. Position a new catalytic converter manifold gasket on the studs.
3. NOTICE: Failure to tighten the catalytic converter manifold nuts to specification before
installing the converter bracket bolts will cause the converter to develop an exhaust leak.
NOTICE: Failure to tighten the catalytic converter manifold nuts to specification a second time
will cause the converter to develop an exhaust leak.
NOTE: Make sure to tighten the nuts in the following sequence in 2 stages.
Position the catalytic converter manifold and tighten the 7 new nuts in the sequence shown, in 2
stages.
• Stage 1: Tighten to 55 Nm (41 lb-ft).
Catalytic Converter - Manifold, Hybrid 4489

• Stage 2: Tighten to 55 Nm (41 lb-ft).
4. Tighten the 2 catalytic converter manifold bracket bolts.

5. Install the 2 catalytic converter manifold shield bracket bolts and the bracket.
6. Position the catalytic converter manifold shield and install the 6 heat shield bolts.
7. Install the exhaust flexible pipe to the catalytic converter.

• Install a new gasket and nuts.
8. Connect the HO2S and the CMS electrical connectors.
Catalytic Converter - Manifold, Hybrid 4490


Manual
REMOVAL AND
INSTALLATION
Catalytic Converter - 3.0L RH
Removal
NOTE: Always install new fasteners and gaskets as indicated. Clean flange faces prior to new gasket
100-02 .
2. Remove the RH front wheel and tire. For additional information, refer to Section 204-04 .
3. Remove the pin-type retainers and position the splash shield aside.
4. Remove the exhaust flexible pipe. For additional information, refer to Exhausexible Pipe - 2.5L, 3.0L
in this section.
5. Remove the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS). For additional
information, refer to Section 303-14B.
6. Remove the roll restrictor bolt and rotate the engine forward.
7. Remove the 5 bolts and position aside the catalytic converter manifold shield.
8. Remove the bolt, 2 nuts and the RH catalytic converter manifold brackets.
9. Remove the 3 nuts and the RH catalytic converter.

• Rotate the RH catalytic converter so the flex-pipe flange opening is facing toward the front of
the vehicle to remove.
• Discard the 3 RH catalytic converter nuts and gasket. Click here to view a video version of
this procedure.
Installation
1. NOTE: Do not tighten the 3 new RH catalytic converter nuts at this time.
Install the RH catalytic converter and a new gasket.
• Loosely install the 3 new nuts.
2. NOTE: Do not tighten the catalytic converter manifold brackets bolt and 2 nuts at this time.
Catalytic Converter - 3.0L RH 4491

Install the RH catalytic converter manifold brackets.
♦ Tighten the 3 RH catalytic converter nuts.

4. NOTE: Do not tighten the 5 catalytic converter manifold shield bolts at this time.
Install the catalytic converter manifold shield.
• Loosely install the 5 bolts.
5. Tighten the RH catalytic converter manifold brackets bolt and 2 nuts.

6. Tighten the catalytic converter manifold shield 5 bolts.

7. Install the roll restrictor bolt.

8. NOTICE: Prior to installation, inspect the Heated Oxygen Sensor (HO2S) and the Catalyst
Monitor Sensor (CMS) wiring harness for damage.
Install the HO2S and CMS . For additional information, refer to Section 303-14B.
9. Install the exhaust flexible pipe. For additional information, refer to Exhaust Flexible Pipe - 2.5L,
3.0L in this section.
10. Install the splash shield and the pin-type retainers.
11. Install the RH front wheel and tire. For additional information, refer to Section 204-04 .



Manual
REMOVAL AND
INSTALLATION
Catalytic Converter - 3.0L LH Manifold
Removal
100-02 .
2. Remove the oil level indicator and tube. For additional information, refer to Section 303-01B .
3. Disconnect the Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS) electrical
connectors.
4. Remove the 2 LH catalytic converter-to-exhaust flexible pipe nuts.

• Discard the gasket and the 2 nuts.
5. Remove the 4 bolts and the LH catalytic converter manifold shield.
6. Remove the 2 LH catalytic converter manifold shield bracket bolts and the shield bracket.
7. Remove the 2 LH catalytic converter manifold bracket bolts and bracket.
8. Remove the 6 nuts and the LH catalytic converter manifold.

• Discard the 6 LH catalytic converter manifold nuts and the gasket.
9. Remove and discard the 6 LH catalytic converter manifold studs.
10. Clean and inspect the catalytic crter manifold. For additional information, refer to Section 303-00 .
Installation
1. Install the 6 new LH catalytic converter manifold studs.

2. Position a new LH catalytic converter manifold gasket on the studs.
3. Position the LH catalytic converter manifold and finger-tighten the 6 new nuts.
4. Install a new gasket and finger-tighten 2 new nuts at the LH catalytic converter-to-exhaust flexible
pipe.
5. NOTICE: Failure to tighten the catalytic converter manifold nuts to specification before
installing the converter bracket bolts will cause the converter to develop an exhaust leak.
NOTICE: Failure to tighten the catalytic converter manifold nuts to specification a second time
will cause the converter to develop an exhaust leak.
NOTE: Make sure to tighten the nuts in the sequence shown in 2 stages.
Catalytic Converter - 3.0L LH Manifold 4494

Position the LH catalytic converter manifold and tighten the 6 new nuts in the sequence shown, in 2
stages.
• Stage 1: Tighten to 20 Nm (177 lb-in).

• Stage 2: Tighten to 20 Nm (177 lb-in).
6. Install the shield bracket and the 2 LH catalytic converter manifold shield bracket bolts.
7. Install the LH catalytic converter manifold bracket and 2 bolts.

8. Position the LH catalytic converter manifold shield and install the 4 bolts.
9. Tighten the 2 new LH catalytic converter-to-exhaust flexible pipe nuts.

10. Connect the HO2S and the CMS electrical connectors.
11. Install the oil level indicator and tube. For additional information, refer to Section 303-01B .
Catalytic Converter - 3.0L LH Manifold 4495


Manual
REMOVAL AND
INSTALLATION
Catalytic Converter - 3.5L RH
All vehicles
100-02 .
2. Remove the exhaust Y-pipe. For additional information, refer to Exhaust Y-Pipe - 3.5L in this section.
All vehicles
4. Remove the 2 bolts and the power steering gear shield.

5. Remove the roll restrictor bolt and rotate the engine forward.
6. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.
7. Remove the 2 bracket-to-RH catalytic converter bolts.

8. Remove the 4 nuts and the RH catalytic converter.

• Discard the 4 RH catalytic converter-to-exhaust manifold nuts and gasket.
9. NOTICE: Prior to Installation, Inspect the CMS wiring harness for damage.
To install, reverse the removal procedure.
• Install a new gasket, nuts and studs as indicated.



Manual
REMOVAL AND
INSTALLATION
Catalytic Converter â 3.5L LH
100-02 .
2. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.
3. Remove the exhaust Y-pipe. For additional information, refer to Exhaust Y-Pipe â 3.5L in this
section.
4. Remove the 2 catalytic converter support bracket-to-transmission bolts.

5. Remove the 4 nuts and the LH catalytic converter.

• Discard the 4 LH catalytic converter-to-exhaust manifold nuts and gasket.

• Install a new gasket, nuts and studs as indicated.
Catalytic Converter â 3.5L LH 4498


Manual
REMOVAL AND
INSTALLATION
Exhaust Flexible Pipe - 2.5L, 3.0L
Removal
NOTICE: Do not excessively bend, twist or allow the exhaust to hang from the flexible pipe or damage
to the exhaust system may occur.
All vehicles
100-02 .
2. If equipped, remove the 6 screws and the underbody shield.
3. Remove and discard the 2 exhaust flexible pipe-to-catalytic converter nuts.

• Discard the gasket.
3.0L vehicles
4. Remove and discard the 2 RH catalytic converter-to-exhaust flexible pipe nuts.

5. Remove and discard the 2 LH catalytic converter-to-exhaust flexible pipe nuts and remove the
exhaust flexible pipe.
2.5L vehicles
6. Remove and discard the 2 catalytic converter manifto-exhaust flexible pipe nuts and remove the
exhaust flexible pipe.
Installation
2.5L vehicles
1. Using a new gasket, install the exhaust flexible pipe and 2 new catalytic converter
manifold-to-exhaust flexible pipe nuts.
Exhaust Flexible Pipe - 2.5L, 3.0L 4499

3.0L vehicles
2. Using a new gasket, install the exhaust flexible pipe and 2 new LH catalytic converter-to-exhaust
flexible pipe nuts.
3. Using a new gasket, install the 2 new exhaust flexible pipe-to-catalytic converter nuts.
All vehicles
4. Using a new gasket, install 2 new exhaust flexible pipe-to-catalytic converter nuts.
5. If equipped, install the underbody shield and the 6 screws.
6. Start the engine and check for exhaust leaks.
Exhaust Flexible Pipe - 2.5L, 3.0L 4500


Manual
REMOVAL AND
INSTALLATION
Exhaust Y-Pipe - 3.5L
1. NOTE: Always install new fasteners and gaskets. Clean flange faces prior to new gasket installation
to make sure of proper sealing.
100-02 .
2. If equipped, remove the 6 screws and the underbody shield.
3. Remove and discard the 2 exhaust Y-pipe-to-resonator nuts.

4. Remove and discard the 2 RH catalytic converter-to-exhaust Y-pipe nuts.

5. Remove and discard the 2 exhaust Y-pipe-to-LH catalytic converter nuts and remove the exhaust
Y-pipe.

• Install new gaskets and nuts.
7. Start the engine and check for exhaust leaks/li>
Exhaust Y-Pipe - 3.5L 4501

Exhaust Y-Pipe - 3.5L 4502


Manual
REMOVAL AND
INSTALLATION
Catalytic Converter - Underbody
100-02 .
2. Remove and discard the 2 exhaust flexible pipe-to-catalytic converter nuts.

3. Remove the Torca® clamp. For additional information, refer to Torca® Clamp in this section.
4. Separate the catalytic converter from the muffler and tail pipe.
• Remove the catalytic converter.

Catalytic Converter - Underbody 4503


Manual
REMOVAL AND
INSTALLATION
Resonator - 3.5L
100-02 .
2. Remove and discard the 2 exhaust Y-pipe-to-resonator nuts.

3. Loosen Torca® clamp nut.

4. Separate the resonator from the muffler and tail pipe and remove the resonator.

Resonator - 3.5L 4504


Manual
REMOVAL AND
INSTALLATION
Muffler and Tailpipe
NOTICE: Do not use oil or grease-based lubricants on the isolators. They may cause deterioration of
the rubber.
NOTICE: Oil or grease-based lubricants on the isolators may cause the exhaust hanger isolator to
separate from the exhaust hanger bracket during vehicle operation.
100-02 .
2. Support the muffler and tail pipe with a suitable jackstand.
3. NOTICE: Do not excessively bend, twist or allow the exhaust to hang from the flexible pipe or
damage to the exhaust system may occur.
Support the catalytic converter with a suitable jackstand.
4. Disconnect the ground clip from the exhaust hanger.
5. Loosen Torca® clamp nut.

6. NOTE: Do not damage or tear the isolators during removal.
Using soapy water, separate the 4 or 5 muffler and tail pipe isolators from the vehicle.
7. Separate the muffler and tail pipe from the catalytic converter and remove the muffler and tail pipe.

• Inspect and replace any isolators damaged or torn during the removal process.
Muffler and Tailpipe 4505


SECTION 310-00: Fuel System - General 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid
Information Workshop Manual
Material
Item Specification
Fill
Capacity
Motorcraft® SAE 5W-20 Premium WSS-M2C930-A -
Synthetic Blend Motor Oil
XO-5W20-QSP (US);
Motorcraft® SAE 5W-20 Super
Premium Motor Oil
CXO-5W20-LSP12 (Canada); or
equivalent
Item Specification
Fuel tank capacity (All-Wheel Drive (AWD) vehicles) 62.46L (16.5 gal)
Fuel tank capacity (Front Wheel Drive (FWD) vehicles) 66.24L (17.5 gal)
Fuel Pressure
2.5L and 3.0L engine running fuel pressure 379-399 kPa (55-58 psi)
3.5L engine running fuel pressure 441-461 kPa (64-67 psi)
Fuel tank filler pipe hose clamp 4 35


Fuel System
Fuel System
The fuel system consists of the:
• All-Wheel Drive (AWD) saddle-type or Front Wheel Drive (FWD) L-shaped fuel tank.
• Fuel Pump (FP) module.
• fuel level sensor assembly (saddle-type fuel tank).
• fuel level sender (mounted on the FP module and, if equipped, on the fuel level sensor assembly).
• Easy Fuel TM (capless) fuel tank filler pipe assembly.
• FP control module on 2.5L and 3.0L vehicles.
• Inertia Fuel Shutoff (IFS) switch on 3.5L vehicles.
• fuel tubes.
• fuel injectors.
• fuel rail.
• Fuel Tank Pressure (FTP) sensor (part of the fuel vapor tube assembly).
The vehicle
• has a single speed Mechanical Retess Fuel System (MRFS) on 3.5L vehicles.
• has a 2-speed MRFS on 2.5L and 3.0L vehicles.
• has either a single container (L-shaped) ( FWD ) or a dual container (saddle-type) ( AWD ) fuel tank.
• has a FP module containing:
♦ an electric FP , which provides pressurized fuel to the fuel rail.
♦ a serviceable fuel level sender.
♦ a check valve, which maintains system pressure after the FP is shut off.
♦ a pressure relief valve for overpressure protection in the event of restricted fuel flow.
♦ a lifetime fuel filter providing filtration to protect the fuel injectors from foreign material.
• has an individual fuel level sensor, AWD vehicles only.
• has a fuel rail-mounted Schrader valve on early build 3.0L vehicles.
• has fuel, vapor and brake tubes in an integrated bundle assembly attached to the underside of the
vehicle by retaining clips.
• has an Easy Fuel TM (capless) fuel tank filler pipe assembly, which cannot be modified in any way.
• has a supplemental refueling adapter located in the luggage compartment.
• has a FTP sensor (part of the fuel vapor tube assembly).
• is equipped with a sequential Multi-Port Fuel Injection (MFI) system.
• uses separately controlled fuel injectors for each cylinder. The fuel injectors are mounted to the intake
manifold.
• fuel injectors are supplied with pressurized fuel from the FP module to the fuel rail.
Fuel System Shutoff Feature
2.5L and 3.0L vehicles
In event of a moderate to severe collision, the vehicle is equipped with a FP shutoff feature that is initiated by
the event notification signal. The event notification signal is provided by the Restraints Control Module
(RCM) to the FP control module. Signal communication between the RCM and the FP control module allows
Fuel System 4509

the PCM to shutoff the FP module. Should the vehicle shut off after a collision due to this feature, restart the
vehicle by first turning the ignition to the OFF position and then turn the ignition to the ON position. In some
instances, the vehicle may not restart the first time and may take an additional attempt.
3.5L vehicles
The FP module is controlled by the PCM. Electrical power to the FP module is provided through the IFS
switch that will de-energize the fuel delivery secondary circuit in the event of a moderate to severe collision.
The IFS switch is a safety device, located under the RH front door scuff plate. Should the vehicle shutoff after
a collision due to this feature, restart the vehicle by first turning the ignition OFF, push the reset button on the
IFS switch, then turn the ignition to the ON position.
2.5L and 3.0L vehicles 4510

Fuel System
Special Tool(s)


NOTE: The following procedure diagnoses a slow to fill concern only. For all other concerns refer to the
Powertrain Control/Emissions Diagnosis (PC/ED) manual.
The fuel tank filler pipe assembly is used to refuel the vehicle. The fuel tank inlet check valve prevents
spitback of fuel during and after refueling. The fuel tank stores the fuel. The fuel tank contains a Fuel Pump
(FP) module. The FP module consists of a fuel level sensor and a FP . The fuel level sender sends a signal to
the fuel gauge informing the driver of how much fuel is in the fuel tank. The FP provides fuel to the fuel tubes
which supply the fuel rail.
During refueling, the fuel tank vents to the atmosphere through the vent and filler pipes, on vehicles without
On-Board Refueling Vapor Recovery (ORVR) systems. In vehicles equipped with ORVR , the fuel tank and
filler pipe are designed so that when the vehicle is being refueled, fuel vapors in the fuel tank travel to the
Evaporative Emission (EVAP) canister, which absorbs the fuel vapors and vents the pressure from the fuel
tank during refueling.
WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the
event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources.
Failure to follow these instructions may result in serious personal injury.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in serious personal injury.
1. Verify the customer's concern by refueling the vehicle and observe the fuel fill rate.
2. Inspect to determine if any of the following mechanical concerns apply.
Mechanical
3.5L vehicles 4511

• Bent, kinked or damaged fuel tank filler pipe

• Bent, kinked or damaged fuel tank filler pipe vent tube (if equipped)
• Incorrect routing of the fuel tank filler pipe
• Incorrect routing of the fuel tank filler pipe vent tube (if equipped)
• Incorrect position of fuel tank filler pipe clamps
• Incorrect position of fuel tank filler pipe vent tube clamps (if equipped)
• Fuel tank mounted vapor tubes bent or damaged
• Evaporative Emission (EVAP) system tubes or hoses bent or damaged
• Accident damage to the fuel tank
• Accident damage to the vehicle effecting the fuel tank filler pipe-to-body
connection
• Unauthorized modifications and/or alterations to the vehicle
• EVAP system fresh air tube plugged (dirt, spider webbing)


• verify the ignition key is in the ON position.
• verify the scan tool operation with a known good vehicle.

418-00 .
(CMDTCs).
8. Clear the continuous DTCs and carry out the self-test diagnostics for the EVAP system.
9. If the DTCs retrieved are related to the concern, go to Evaporative Emission (EVAP) System DTC
Chart. For PCM-related DTCs, refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
For all other DTCs, refer to Section 419-10 .
DTC Chart
Evaporative Emission (EVAP) System DTC Chart
Fuel System 4512


P0446 Evaporative Emission System Vent Control Circuit GO to Pinpoint Test A .
P0451 Evaporative Emission System Pressure Sensor/Switch Range/Performance GO to Pinpoint Test A .
P0452 Evaporative Emission System Pressure Sensor/Switch Low GO to Pinpoint Test A .
P0453 Evaporative Emission System Pressure Sensor/Switch High GO to Pinpoint Test A .
P0454 Evaporative Emission System Pressure Sensor/Switch Intermittent GO to Pinpoint Test A .
P1450 Unable to Bleed up Fuel Tank Vacuum GO to Pinpoint Test A .
P1451 Evaporative Emission System Vent Control Circuit GO to Pinpoint Test A .
P260F Emission System Monitoring Processor Performance GO to Pinpoint Test A .
Symptom Chart
Symptom Chart
Pinpoint Test
Pinpoint Test A: Slow to Fill
Normal Operation
Under normal operation, fuel should flow at a steady rate through the fuel tank filler pipe into the fuel tank.
As fuel enters the fuel tank, air is vented through the filler pipe or the On-Board Refueling Vapor Recovery
(ORVR) system.

• Fuel tank filler pipe vent tube, if equipped
• Fuel tank filler pipe
• Evaporative Emission (EVAP) system
• Fuel tank inlet check valve (part of the fuel tank)
• Fuel level vent valve (part of the fuel tank)
PINPOINT TEST A: SLOW TO FILL

A1 CARRY OUT INSPECTION AND
VERIFICATION
Yes
• Carry out inspection and verification. REPAIR or INSTALL new components to correct the
• Was the cause of the concern found? concern.
No
GO to A2 .
A2 CHECK THE SYSTEM FOR ANY
EVAP DTCs

• Connect the scan tool. Yes

• Check the system for any of the REFER to Powertrain Control/Emissions Diagnosis
following EVAP DTCs: P0446, P0451, (PC/ED) manual to diagnose the EVAP system.
P0452, P0453, P0454, P1450, P1451
and P260F. No
• Are any of these DTCs present? GO to A3 .
A3 MONITOR THE FTP WHILE
FILLING THE FUEL TANK
Yes
• Monitor the Fuel Tank Pressure (FTP) GO to A5 .
reference value while filling the fuel
tank. Refer to Powertrain No
Control/Emissions Diagnosis (PC/ED) GO to A4 .
manual.
• Is FTP within specification?
A4 MONITOR THE FTP WHILE
FILLING THE FUEL TANK WITH THE
EVAP SYSTEM DISCONNECTED
Yes
• Disconnect the fuel tank-to- EVAP INSPECT the EVAP system for blockage or
canister quick connect coupling at the restrictions. REPAIR the blockage or restriction. If the
EVAP canister. Refer to Quick Connect restriction or blockage cannot be repaired, INSTALL
Coupling in this section. new EVAP system components.
• Monitor the FTP reference value while
filling the fuel tank. Refer to Powertrain No
Control/Emissions Diagnosis (PC/ED) GO to A5 .
manual.
• Is FTP within specification?
A5 CHECK THE FUEL TANK FILLER
PIPE ASSEMBLY FOR BLOCKAGE OR
RESTRICTION
Yes
• Remove the fuel tank filler pipe If possible, REPAIR the blockage or restriction. If the
assembly. Refer to Section 310-01A . blockage or restriction cannot be repaired, INSTALL a
• Inspect the fuel tank filler pipe and fuel new fuel tank filler pipe or fuel tank filler pipe vent
tank filler pipe vent tube (if equipped) tube.
for a blockage or restriction.
• Is the fuel tank filler pipe or fuel tank No
filler pipe vent tube (if equipped) GO to A6 .
blocked or restricted?
A6 CHECK THE FUEL TANK INLET
CHECK VALVE
Yes
• Inspect the fuel tank inlet check valve If possible, REPAIR the restriction. If the restriction
for restriction or sticking. cannot be repaired, INSTALL a new fuel tank. REFER
• Is the fuel tank filler pipe inlet check to Section 310-01A .
valve restricted or sticking?
No
INSTALL a new fuel tank. REFER to Section 310-01A
.
PINPOINT TEST A: SLOW TO FILL 4514

PINPOINT TEST A: SLOW TO FILL 4515

Fuel System Pressure Release
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio
equipment of any type when working on or near any fuel-related component. Highly flammamixtures
are always present and may be ignited. Failure to follow these instructions may result in serious
personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components,
relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains
under high pressure, even when the engine is not running. Failure to follow this instruction may result
in serious personal injury.
1. Position aside the LR quarter panel luggage compartment trim.
2. Disconnect the Fuel Pump (FP) control module electrical connector.
3.5L vehicles
3. Remove the RF door scuff plate.
4. Disconnect the Inertia Fuel Shutoff (IFS) switch.
Fuel System Pressure Release 4516

All vehicles
5. Start the engine and allow it to idle until it stalls.
6. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel system
pressure has been released.
7. Turn the ignition switch to the OFF position.
8. When fuel system service is complete, reconnect the FP control module electrical connector.
9. Position the LR quarter panel luggage compartment trim.
3.5L vehicles
10. When fuel system service is complete, reconnect the IFS switch electrical connector.
11. Install the RF door scuff plate.
All vehicles
12. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait 3 seconds to pressurize the fuel system.
13. NOTE: Carry out a Key ON Engine OFF (KOEO) visual inspection for fuel leaks prior to starting the
engine.
Start the vehicle and check the fuel system for leaks.
Fuel System Pressure Release 4517

Fuel System Pressure Test
Special Tool(s)
Adapter, Fuel Pressure Test

310-180
Fuel Pressure Test Kit

310-D009 (D95L-7211A)
equipment of any type when working on or near any fuel-related component. Highly flammable
mixtures are always present and may be ignited. Failure to follow these instructions may result in
NOTE: Early build 3.0L engines are equipped with a Schrader valve on the fuel rail. Late build 3.0L engines
do not have a Schrader valve.
2.5L engine
1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release in
this section.
2. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .
3. Disconnect the fuel jumper tube-to-fuel rail quick connect coupling. For additional information, refer
to Quick Connect Coupling in this section.
4. Install the Fuel Pressure Test Kit between the fuel jumper tube and the fuel rail.
Fuel System Pressure Test 4518

5. NOTE: The Fuel Pump (FP) control module was disconnected in the fuel system pressure release.
Connect the FP control module electrical connector.
6. Connect the battery ground cable. For additional information, refer to Section 414-01 .
Early build 3.0L engine
7. Remove the fuel rail Schrader valve cap.
8. Install the Fuel Pressure Test Kit to the fuel rail Schrader valve.
Late build 3.0L engine
9. Disconnect the fuel jumper tube-to-fuel tube quick connect coupling. For additional information, refer
to Quick Connect Coupling in this section.
10. Install the Fuel Pressure Test Kit between the fuel jumper tube and the fuel tube.
3.5L engine
this section.

13. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12C .
14. Disconnect the fuel tube-to-fuel rail spring lock coupling. For additional information, refer to Spring
Lock Couplings in this section.
15. Install the Fuel Pressure Test Adapter and Fuel Pressure Test Kit between the fuel tube and the fuel
rail.
16. NOTE: The ACL outlet pipe must be installed prior to completing the fuel system pressure test.
Install the ACL outlet pipe. For additional information, refer to Section 303-12C .
17. NOTE: The Inertia Fuel Shutoff (IFS) switch was disconnected in the fuel system pressure release.
Connect the IFS switch electrical connector.
All engines
19. NOTE: Carry out a Key ON Engine OFF (KOEO) visual inspection for fuel leaks prior to completing
the fuel system pressure test.
NOTE: After completion of the fuel system pressure test, open the drain valve on the Fuel Pressure
Test Kit and release any residual fuel into a suitable container prior to removing the tool.
Test the fuel system pressure to make sure it is within the specified range. For additional information,
refer to Specifications in this section.


Fuel Tank Draining - 2.5L
Special Tool(s)
Fuel Storage Tanker

164-R3202 or equivalent
Fuel Tank Sender Unit Wrench

310-123
NOTE: For vehicles with an inaccurate or inoperable fuel gauge, follow the instructions for draining a fuel
tank with more than three-fourths of a tank of fuel.
All vehicles
this section.
Vehicles with more than three-fourths of a tank of fuel
3. NOTE: The supplemental refueling adapter is located in the luggage compartment.
Install the supplemental refueling adapter and a length of semi-rigid fuel drain tube into the Easy Fuel
TM (capless) fuel tank filler pipe until the tube enters the fuel tank.
Fuel Tank Draining - 2.5L 4522

4. NOTE: This step will remove approximately one-fourth tank of the fuel from a completely full fuel
tank and the majority of any residual fuel in the fuel tank filler pipe, lowering the fuel level below the
Fuel Pump (FP) module mounting flange.
Attach the Fuel Storage Tanker to the fuel drain tube and remove one-fourth (approximately 4
gallons) of fuel from the tank.
All vehicles
5. Remove the rear seat lower cushion. For additional information, refer to Section 501-10 .
6. Remove the 4 screws and the FP module access cover.
7. NOTE: Clean the FP module connections, couplings, flange surfaces and the immediate surrounding
area of any dirt or foreign material.
Disconnect the FP module electrical connector.
8. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage.
Disconnect the fuel tube-to- FP module quick connect coupling. For additional information, refer to
Section 310-00 .
9. NOTE: Make sure to install a new FP module O-ring seal.

Install the Fuel Tank Sender Unit Wrench, remove the FP module lock ring.
• Discard the FP module O-ring seal.
10. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float
arm.
Position the FP module aside and insert the tube from the Fuel Storage Tanker into the FP module
aperture and drain as much fuel from the fuel tank as possible.

Fuel Tank Draining - 3.0L Front Wheel Drive (FWD)
Special Tool(s)
Fuel Storage Tanker


310-123
tank with more than three-fourths of a tank of fuel.
All vehicles
this section.
Vehicles with more than three-fourths of a tank of fuel
NOTE: The Easy Fuel TM (capless) fuel tank filler pipe on 3.0L vehicles have an anti-siphon grate that will
not allow a fuel drain tube to penetrate the fuel tank and requires the following steps to drain the fuel.
100-02 .
4. NOTE: Index-mark the fuel tank filler pipe hose and the clamp prior to removal for correct
installation.
Fuel Tank Draining - 3.0L Front Wheel Drive (FWD) 4525

Release the clamp and disconnect the hose from the fuel tank filler pipe.
5. Insert a semi-rigid fuel drain tube into the fuel tank filler pipe hose until it enters the fuel tank.
6. NOTE: This step is to remove approximately one-fourth tank of the fuel from a completely full fuel
tank, lowering the fuel level below the Fuel Pump (FP) module mounting flange.
All vehicles

Section 310-00 .
Install the Fuel Tank Sender Unit Wrench and remove the FP module lock ring.
arm.


Fuel Tank Draining - 3.0L All Wheel Drive (AWD)
Special Tool(s)
Fuel Storage Tanker


310-123
tank with more than one-half of a tank of fuel.
All vehicles
this section.
Vehicles with more than one-half of a tank of fuel
100-02 .
installation.
Fuel Tank Draining - 3.0L All Wheel Drive (AWD) 4529

6. NOTE: This step is to remove approximately one-half tank of the fuel from a completely full fuel
tank, lowering the fuel level below the Fuel Pump (FP) module mounting flange.
Attach the Fuel Storage Tanker to the fuel drain tube and remove one-half (approximately 9 gallons)
of fuel from the tank.
All vehicles

Section 310-00 .
arm.
13. Remove the 3 screws and the fuel level sensor access cover.
14. NOTE: Clean the fuel level sensor electrical connector, flange surface and the immediate surrounding
Disconnect the fuel level sensor electrical connector.

Release the lock tab and rotate the fuel level sensor counterclockwise approximately one-fourth turn,
lift and position aside.
16. Insert the tube from the Fuel Storage Tanker into the fuel level sensor aperture and drain the
remainder of the fuel from the fuel tank.

Fuel Tank Draining - 3.5L
Special Tool(s)
Fuel Storage Tanker


310-123
NOTE: For (Front Wheel Drive (FWD)) vehicles with an inaccurate or inoperable fuel gauge, follow the
instructions for draining a fuel tank with more than three-fourths of a tank of fuel.
NOTE: For (All-Wheel Drive (AWD)) vehicles with an inaccurate or inoperable fuel gauge, follow the
instructions for draining a fuel tank with more than one-half of a tank of fuel.
All vehicles
this section.
Front Wheel Drive (FWD) vehicles with more than three-fourths tank of fuel

5. NOTE: This step will remove approximately one-fourth tank of the fuel from a completely full fuel
All-Wheel Drive (AWD) vehicles with more than one-half tank of fuel
tank, lowering the fuel level below the FP module mounting flange.
FWD vehicles
AWD vehicles

All vehicles
Section 310-00 .
Install the Fuel Tank Sender Unit Wrench, remove the FP module lock ring.
arm.
Position the FP module aside and insert the tube from the fuel storage tanker into the FP module

AWD vehicles
15. NOTE: Clean the fuel level sensor electrical connector, flange surface and the immediate surrounding
Release the lock tab and rotate the fuel level sensor counterclockwise approximately one-fourth turn,
lift and position aside.
17. Insert the tube from the Fuel Storage Tanker into the fuel level sensor aperture and drain the
remainder of the fuel from the fuel tank.


Quick Connect Coupling
Special Tool(s)
Disconnect Tool, Fuel Pipe (5/16")

310-040
Material
Item Specification
Motorcraft® SAE 5W-20 Premium WSS-M2C930-A
XO-5W20-QSP (US); Motorcraft®
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada);
or equivalent
Disconnect - Type I
NOTICE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove
any foreign material from the connector retaining clip area before separating from the tube or damage
to the tube or connector retaining clip can occur. Apply clean engine oil to the end of the tube before
inserting the tube into the connector.
NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
essential that absolute cleanliness is observed when working with these components or component
damage can occur. Always install plugs to any open orifices or tubes.
Quick Connect Coupling 4538

NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components which
may cause fuel leaks.
1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For additional
information, refer to Fuel System Pressure Release in this section.
3. Depress the locking tab and release the quick connect coupling from the tube.
Connect - Type I
1. NOTE: Make sure the retainer clip is fully seated and locked onto the tube by pulling on the quick
connect coupling.
Install the quick connect coupling onto the tube until it is fully seated.
Disconnect - Type II
on or near auel-related component. Highly flammable mixtures are always present and may be ignited.

2. Release the lock tab on the quick connect coupling.
3. Separate the quick connect coupling from the fitting.
Connect - Type II
1. NOTE: Apply clean engine oil to the O-ring seals.
NOTE: Make sure the retainer clip is fully seated and locked onto the tube by pulling on the quick
connect coupling.
Release the lock tab and install the quick connect coupling onto the fitting.
2. Apply the lock tab into the latched position.

Disconnect - Type III
3. Release the quick connect coupling lock tab.

4. Rotate the primary locking tab to the fully opened position and squeeze the secondary locking tabs to
release the locking mechanism.
5. Push the locking mechanism outward and release the tube.
6. Remove the quick connect coupling from the tube.
Connect - Type III
2. Depress the retainer clip until it is flush with the quick connect coupler housing and is fully seated on
the tube.

connect coupling.
Rotate the primary locking tab on the retainer clip to the closed position.
Disconnect - Type IV
3. Squeeze the quick connect coupling retainer clip tabs to release the locking mechanism.

4. Push the locking mechanism outward to release the tube.
Connect - Type IV
Install the quick connect coupling onto the tube.
2. Depress the quick connect coupling locking mechanism into the locked position.
connect coupling.
Visually inspect and verify that the locking mechanism is flush with the quick connect coupling
housing and that the tabs are locked in place.

Disconnect - Type V
3. Install the Fuel Pipe Disconnect Tool on the tube and push into the quick connect coupling locking
clip to release.

Connect - Type V
1. NOTE: Apply ean engine oil to the O-ring seals.
NOTE: Make sure the retainer clip is fully seated and locked onto the tube by pulling on the quick
connect coupling.
Disconnect - Type VI
WARNING: Do not carry persal electronic devices such as cell phones, pagers or audio equipment
of any type when working on or near any fuel-related component. Highly flammable mixtures are
always present and may be ignited. Failure to follow these instructions may result in serious personal
injury.

3. Depress the legs of the retainer clip and position the clip in an outward position.
4. Disconnect the quick connect coupling from the tube.
Connect - Type VI
1. NOTE: Apply clean engine oil to the end of the tube and quick connect coupling O-ring seals.
Install the quick connect coupling onto the tube until fully seated.
connect coupling.
Press the retainer clip into the quick connect coupling body until flush and the legs are locked in
place.
Disconnect - Type VII

3. Push the tube into the quick connect coupling and depress the release mechanism.
4. Disconnect the quick connect coupling from the tube.
Connect - Type VII

1. NOTE: Apply clean engine oil to the end of the tube and quick connect coupling O-ring seals.
Install the quick connect coupling onto the tube until fully seated.
2. Pull the tube and the coupling in separate directions to ensure the quick connect coupling is secured
on the tube.
3. Connect the battery ground cable. For additiol information, refer to Section 414-01 .

Spring Lock Couplings
Special Tool(s)
Disconnect Tool, Spring Lock Coupling

310-S039 (T90T-9550-S) or equivalent
Material
Item Specification
Motorcraft® SAE 5W-20 Premium
SAE 5W-20 Super Premium Motor Oil
equivalent WSS-M2C930-A
Disconnect
Spring Lock Couplings 4550

this section.
3. Install the Spring Lock Coupling Disconnect Tool on the tube and push into the spring lock coupling
to release.
4. Separate the spring lock coupling from the tube.
Connect
1. NOTE: Lubricate the fuel tube with clean engine oil.
Align and push the spring lock coupling onto the tube until a click is heard.
2. Pull on the coupling to make sure it is fully engaged.



SECTION 310-01A: Fuel Tank and Lines
Workshop Manual
Material
Item Specification
Fill
Capacity
Synthetic Blend Motor Oil (US);
Premium Motor Oil (Canada)
XO-5W20-QSP (US);
CXO-5W20-LSP12 (Canada)
Item Specification
Fuel tank capacity (All-Wheel Drive (AWD) vehicles) 62.46L (16.5 gal)
Fuel tank capacity (Front Wheel Drive (FWD) vehicles) 66.24L (17.5 gal)

Fuel level sensor access cover screws 2 - 18
Fuel Pump (FP) module access cover screws 2 - 18
Fuel tank filler pipe bracket bolt 7 - 62
Fuel tank filler pipe bracket nut 7 - 62
Fuel tank filler pipe heat shield nuts 9 - 80
Fuel tank filler pipe hose clamp 4 - 35
Fuel tank strap bolts 40 30 -
Inertia Fuel Shutoff (IFS) switch bolt 2 - 18
LR parking brake cable assembly bracket bolts 23 17 -
Lower crossover support brace nuts 76 56 -



Workshop Manual
Fuel Tank and Lines
Fuel System
The fuel system consists of:
• a single-speed Mechanical Returnless Fuel System (MRFS) (3.5L vehicles).

• a 2-speed MRFS (2.5L and 3.0L vehicles).
• an All-Wheel Drive (AWD) saddle-type or Front Wheel Drive (FWD) L-shaped fuel tank.
• an Easy Fuel TM (capless) fuel tank filler pipe assembly, which cannot be modified in any way.
• a Fuel Pump (FP) module containing:
• fuel, vapor and brake tubes in an integrated bundle assembly attached to the underside of the vehicle
by retaining clips.
• an Inertia Fuel Shutoff (IFS) switch (3.5L vehicles).
• a FP control module (2.5L and 3.0L vehicles).
• an individual fuel level sensor, AWD vehicles only.
In event of a moderate to severe collision, the vehicle is equipped with a FP shutoff feature that is initiated by
the event notification signal. The event notification signal is provided by the Restraints Control Module
(RCM) to the FP control module. Signal communication between the RCM and the FP control module allows
the PCM to shutoff the FP module. Should the vehicle shut off after a collision due to this feature, restart the
vehicle by first turning the ignition to the OFF position and then turn the ignition to the ON position. In some
instances, the vehicle may not restart the first time and may take an additional attempt.
3.5L vehicles
The FP module is controlled by the PCM. Electrical power to the FP module is provided through the IFS
switch that will de-energize the fuel delivery secondary circuit in the event of a moderate to severe collision.
The IFS switch is a safety device, located under the RH front door scuff plate. Should the vehicle shutoff after
a collision due to this feature, restart the vehicle by first turning the ignition OFF, push the reset button on the
IFS switch, then turn the ignition to the ON position.
Fuel Tank and Lines 4555

3.5L vehicles 4556


Workshop Manual
Fuel Tank and Lines

SECTION 310-01A: Fuel Tank and 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop
Lines Manual
Fuel Tank and Filler Pipe - Exploded View
Fuel Tank Supports and Shields (Front Wheel Drive (FWD) Vehicles)

1 9092 RH fuel tank strap
2 W505444 Fuel tank strap bolt (4 required)
3 9092 LH fuel tank strap
4 9A031 Fuel tank heat shield
5 W700430 Fuel tank heat shield nut (2 required)
6 9B328 Fuel tank heat shield clip (2 required)
8 5411268 Fuel tank filler pipe heat shield
9 W707142 Fuel tank filler pipe heat shield nut (3 required)
10 529330 Fuel tank filler pipe heat shield bracket
11 W701259 Splash shield pin-type retainer (6 required)
12 5428371 LR splash shield
13 N807379 Splash shield rivet (3 required)
&nb
Fuel Tank and Filler Pipe ( FWD Vehicles)
Fuel Tank and Filler Pipe - Exploded View 4558

Part
1 W807011 Fuel Pump (FP) module access cover screw (4 required)
2 54111 FP module access cover
3 9C385 FP module lock ring
4 14A464 FP module electrical connector
5 - Fuel tube-to- FP module quick connect coupling (part of
9J279)
6 9J279 Fuel tube
7 9H307 FP module
9 9002 Fuel tank
10 - Fuel vapor tube assembly-to-fuel tank quick connect
coupling (part of 9A228)
11 9A228 Fuel vapor tube assembly
12 W525937 Fuel tank filler pipe hose clamp
13 9047 Fuel tank filler pipe hose
14 - Fuel vapor tube assembly-to-fuel tank filler pipe
recirculation tube quick connect coupling (part of 9A228)
15 N806543 Fuel tank filler pipe bracket nut
16 - Fuel tank filler pipe recirculation tube (part of 9034)
17 27936 Fuel tank filler pipe housing
18 9K072 Information bezel
19 9B178 Fuel tank filler pipe
20 W707398 Fuel tank filler pipe bracket bolt
21 - Fuel tank filler pipe housing retainer (3 required) (part of
27936)
Fuel Tank and Filler Pipe ( FWD Vehicles) 4559

Fuel Tank Supports and Shields (All-Wheel Drive (AWD) Vehicles)

8 5428371 LR splash shield
Fuel Tank and Filler Pipe ( AWD Vehicles)
Fuel Tank Supports and Shields (All-Wheel Drive (AWD) Vehicles) 4560
Part
1 W807011 Fuel level sensor access cover screw (3 required)
2 54111 Fuel level sensor access cover
3 14A464 Fuel Pump (FP) module electrical connector
5 14A464 Fuel level sensor electrical connector
6 9275 Fuel level sensor
7 9002 Fuel tank
8 - Fuel tube-to- FP module quick connect coupling (part of
9J279)
9 9J279 Fuel tube
10 - Internal crossover fuel tube-to- FP module quick connect
coupling (part of 9002)
11 - Internal crossover fuel tube (part of 9002)
12 9H307 FP module
13 9276 FP module O-ring seal
14 W807011 FP module access cover screw (3 required)
15 54111 span> module access cover
16 - Fuel vapor tube assembly-to-fuel tank quick connect
coupling (part of 9A228)
recirculation tube quick connect coupling (part of 9A228)
22 - Fuel tank filler pipe recirculation tube (part of 9034)
27 9K072 Information bezel
28 - Fuel tank filler pipe housing retainer (3 required) (part of
27936)
Fuel Tank and Filler Pipe ( AWD Vehicles) 4561

Fuel Tank and Filler Pipe ( AWD Vehicles) 4562

Lines Manual
Fuel Tank - Front Wheel Drive (FWD)
Special Tool(s)
Powertrain Lift
100-02 .
2. Drain the fuel tank. For additional information, refer to Section 310-00 .
3. Remove the muffler and tailpipe. For additional information, refer to Section 309-00 .
4. NOTE: Some residual fuel may remain in the fuel tank filler pipe after draining the fuel tank.
Carefully drain any remaining fuel into a suitable container.
Release the clamp and disconnect the fuel tank filler pipe hose from the fuel tank.
5. Disconnect the fuel vapor tube assembly-to-fuel tank quick connect coupling. For additional
information, refer to Section 310-00 .
Fuel Tank - Front Wheel Drive (FWD) 4563

6. Remove the 4 nuts, 2 clips and release the heat shield from the fuel tank.
7. Install the Powertrain Lift under the fuel tank.
8. Remove the 4 bolts and the 2 fuel tank straps.

9. Carefully lower and remove the fuel tank from the vehicle.
Fuel Tank - Front Wheel Drive (FWD) 4564

Lines Manual
Fuel Tank - All Wheel Drive (AWD)
Special Tool(s)
Powertrain Lift
100-02 .
4. Remove the driveshaft. For additional information, refer to Section 205-01 .

7. Partially lower the fuel tank enough to access the fuel tank filler pipe hose clamp.
Fuel Tank - All Wheel Drive (AWD) 4565

Fuel Tank - All Wheel Drive (AWD) 4566

Lines Manual
Fuel Tank Filler Pipe - Front Wheel Drive (FWD)
Special Tool(s)
Fuel Storage Tanker

100-02 .
3. If the vehicle is equipped with a dual exhaust system, remove the muffler and tailpipe. For additional
TM (capless) fuel tank filler pipe.
Fuel Tank Filler Pipe - Front Wheel Drive (FWD) 4567

5. Attach the Fuel Storage Tanker to the fuel drain tube and remove any residual fuel in the fuel tank
filler pipe.
6. Remove the LR wheel and tire. For additional information, refer to Section 204-04 .
7. Remove the 3 rivets, 6 pin-type retainers and the LR splash shield.
8. Remove the 3 nuts and the fuel tank filler pipe heat shield.
9. Remove the fuel tank filler pipe bolt and nut.

10. Disconnect the fuel vapor tube assembly-to-fuel tank filler pipe recirculation tube quick connect
coupling. For additional information, refer to Section 310-00 .
11. Remove the information bezel.
12. Release the 3 retainers and remove the fuel tank filler pipe housing.
13. NOTE: Some fuel may remain in the fuel tank filler pipe after the initial drain. Carefully drain any
residual fuel into a suitable container.
14. NOTE: The fuel tank filler pipe assembly has to be directed upward and partially out of the fuel door
opening, then it can be lowered and removed from the vehicle.
Remove the fuel tank filler pipe assembly from the vehicle.


Lines Manual
Fuel Tank Filler Pipe - All Wheel Drive (AWD)
Special Tool(s)
Fuel Storage Tanker

Powertrain Lift
WARN Do not carry personal electronic devices such as cell phones, pagers or audio equipment of
any type when working on or near any fuel-related component. Highly flammable mixtures are always
100-02 .
Fuel Tank Filler Pipe - All Wheel Drive (AWD) 4570

filler pipe.
7. Remove the 3 rivets, 6 pin-type retainers and the LR splash shield.
9. Remove the fuel tank filler pipe bolt and nut.


15. Partially lower the fuel tank enough to access the fuel tank filler pipe hose clamp.
17. NOTE: The fuel tank filler pipe assembly has to be directed upward and partially out of the fuel door
opening, then it can be lowered and removed from the vehicle.
Remove the fuel tank filler pipe assembly from the vehicle.


Lines Manual
Fuel Pump Module - Front Wheel Drive (FWD)
Special Tool(s)
Fuel Storage Tanker


310-123
Material
Item Specification
XO-5W20-QSP (US);
ignited. Failure to follow tnstructions may result in serious personal injury.
NOTE: Vehicles with an inaccurate or inoperable fuel gauge, follow the instructions for draining a fuel tank
with more than three-fourths of a tank of fuel.
All vehicles
1. Release the fuel system pressure. For additional information, refer to Section 310-00 .
Fuel Pump Module - Front Wheel Drive (FWD) 4573

2.5L and 3.5L vehicles with more than three-fourths of a tank of fuel
3.0L vehicles with more than three-fourths of a tank of fuel
100-02 .
filler pipe.
installation.

All vehicles

14. Disconnect the fuel tube-to- FP module quick connect coupling. For additional information, refer to
Section 310-00 .
15. NOTE: Place absorbent pads on the floor pan in the immediate area in case of fuel spills. Carefully
remove the FP module from the vehicle to avoid fuel spillage inside the vehicle.
NOTE: Make sure to install a new FP module O-ring seal.
arm.

NOTE: The FP module will have residual fuel remaining internally, drain into a suitable container.
Carefully remove the FP module from the fuel tank.
17. NOTICE: Inspect the mating surfaces of the Fuel Pump (FP) module flange and the fuel tank
O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank
flange or the fuel tank. Install a new FP module or fuel tank if the O-ring seal contact area is
bent, scratched or corroded.
NOTE: To install, apply clean engine oil to the new O-ring seal.
Remove and discard the FP module O-ring seal.

• Make sure the alignment tab on the FP module and the fuel tank meet before tightening the
FP module lock ring.

Lines Manual
Fuel Pump Module - All Wheel Drive (AWD)
Special Tool(s)
Fuel Storage Tanker


310-123
Material
Item Specification
XO-5W20-QSP (US);
ignited. Failure to follow theseuctions may result in serious personal injury.
NOTE: Vehicles with an inaccurate or inoperable fuel gauge, follow the instructions for draining a fuel tank
with more than one-half of a tank of fuel.
All vehicles
Fuel Pump Module - All Wheel Drive (AWD) 4577

2.5L and 3.5L vehicles with more than one-half of a tank of fuel
3.0L vehicles with more than one-half of a tank of fuel
100-02 .
filler pipe.
installation.

All vehicles

Section 310-00 .
16. Carefully lift the FP module out of the fuel tank enough to access and release the internal fuel tube-to-
FP module quick connect coupling. For additional information, refer to Section 310-00 .

arm.
Carefully remove the FP module from the fuel tank.


Lines Manual
Fuel Level Sensor
Special Tool(s)
Fuel Storage Tanker

Material
Item Specification
XO-5W20-QSP (US);
serious personal inry.
NOTE: Only All-Wheel Drive (AWD) vehicles are equipped with a fuel level sensor (sub-side module) in the
RH side of the saddle-type tank.
All vehicles
Fuel Level Sensor 4581

100-02 .
filler pipe.
installation.
tank, lowering the fuel level below the fuel level sensor mounting flange.

tank, lowering the fuel level below the fuel level sensor mounting flange.
All vehicles
12. NOTE: Clean the fuel level sensor connections, flange surfaces and the immediate surrounding area
of any dirt or foreign material.
13. NOTE: Place absorbent pads in the general work area in case of fuel spillage.
Release the lock tab, rotate the fuel level sensor counterclockwise approximately one-fourth turn and
lift upward.
14. NOTICE: Inspect the mating surfaces of the fuel level sensor flange and the fuel tank O-ring
seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange
or the fuel tank. Install a new fuel level sensor or fuel tank if the O-ring seal contact area is
NOTICE: The fuel level sensor must be handled carefully to avoid damage to the float arm.
NOTE: Carefully remove the fuel level sensor from the fuel tank to avoid fuel spillage inside the
vehicle.
Carefully lift and remove the fuel level sensor from the fuel tank.

• Make sure the fuel level sensor locking tab is correctly positioned.


Lines Manual
Fuel Level Sender

1 9H307 Fuel Pump (FP) module
2 9A299 Fuel level sender
3 - Fuel level sender electrical connector (part of 9A299)
NOTE: The fuel level sender is serviced as part of a kit (9A299).
1. Remove the Fuel Pump (FP) module. For additional information, refer to Fuel Pump Module - Front
Wheel Drive (FWD) or Fuel Pump Module - All Wheel Drive (AWD) in this section.
2. Disconnect the fuel level sender electrical connector.
3. Depress the lock tab and slide the fuel level sender upwards and remove.
Fuel Level Sender 4585

4. To install, reverse the removal edure.

Lines Manual
Fuel Lines - Front Wheel Drive (FWD)
2.5L Vehicles
Part
1 W707142 Heat shield nut (2 required)
2 54017 Heat shield
4 020602 Heat shield
5 9G271 Vapor jumper tube
6 - Vapor jumper tube-to-vapor tube quick connect coupling
(part of 9G271)
7 9J280 Fuel jumper tube
8 - Fuel jumper tube-to-fuel tube quick connect coupling
(part of 9J280)
9 5884 Lower crossover support brace
10 W580415 Lower crossover support brace nut (4 required)
11 - Fuel tube bundle retaining clip (part of 9J279) (9
required)
12 9J279 Fuel tube
13 - Fuel tube-to-Fuel Pump (FP) module quick connect
coupling (part of 9J279)
14 9J279 Vapor tube
15 - Vapor jumper tube-to-ck connect coupling (part of
9J279)
16 9J279 Vapor jumper tube
17 - Vapor jumper tube-to-Evaporative Emission (EVAP)
canister quick connect coupling (part of 9J279)
18 - Stone shield (part of 2A815)
19 2A815 LR parking brake cable assembly
Fuel Lines - Front Wheel Drive (FWD) 4587

20 W505263 Rear parking brake cable assembly bolt
3.0L Vehicles
Part
2 54017 Heat shield
6 - Vapor jumper tube-to-vapor tube
quick connect coupling (part of
9G271)
8 - Fuel jumper tube-to-fuel tube
9J280)
10 W580415 Lower crossover support brace 11 - Fuel tube bundle
nut (4 required) retaining clip
(part of 9J279) (9
required)
12 9J279 Fuel tube
13 - Fuel tube-to-Fuel Pump (FP)
module quick connect coupling
(part of 9J279)
14 9J279 Vapor tube
15 - Vapor jumper tube-to-vapor tube
9J279)
17 - Vapor jumper tube-to-Evaporative
Emission (EVAP) canister quick
2.5L Vehicles 4588

connect coupling (part of 9J279)

20 W505263 Rear parking brake cable
assembly bolt
3.5L Vehicles
Part
2 54017 Heat shield
6 - Vapor jumperor tube quick connect coupling (part of
9G271)
(part of 9J280)
required)
12 9J279 Fuel tube
14 9J279 Vapor tube
(part of 9J279)
3.0L Vehicles 4589


on or near any fuel-related component. Highly flammable mixtures are always may be ignited. Failure
All vehicles
100-02 .
3.5L vehicles
5. NOTE: The lower cowl panel must be removed to access the fuel and vapor tube quick connect
couplings.
Remove the lower cowl panel. For additional information, refer to the Cowl Panel Grille procedure in
Section 501-02 .
All vehicles
6. Remove the 4 nuts and the 2 heat shields.
7. NOTE: Some residual fuel may remain in the fuel tubes after releasing the fuel system pressure.
When disconnecting or removing any fuel tubes, carefully drain any residual fuel into a suitable
container.
3.5L Vehicles 4590

Disconnect the fuel jumper tube-to-fuel tube quick connect coupling. For additional information, refer
to Section 310-00 .
8. Disconnect the vapor jumper tube-to-vapor tube quick connect coupling. For additional information,
refer to Section 310-00 .
9. Remove the 4 nuts and the lower crossover support brace.

10. Remove the fuel tank. For additional information, refer to Fuel Tank - Front Wheel Drive (FWD) in
this section.
11. NOTE: The LR parking brake cable bolt also retains a stone shield. Position the cable and shield
aside.
Remove the bolt and position the LR parking brake cable assembly aside.
13. Release the 9 fuel tube bundle retaining clips and remove the fuel and vapor tubes.
14. Disconnect the vapor jumper tube-to-Evaporative Emission (EVAP) canister quick connect coupling
and remove the vapor jumper tube. For additional information, refer to Section 310-00 .
3.5L Vehicles 4591

Lines Manual
Fuel Lines - All Wheel Drive (AWD)
3.0L Vehicles
Part
2 54017 Heat shield
(part of 9G271)
(part of 9J280)
required)
12 9J279 Fuel tube
14 9J279 Vapor tube
15 - Vapor jumper tube-to-vapoonnect coupling (part of
9J279)
Fuel Lines - All Wheel Drive (AWD) 4592

3.5L Vehicles
Part
2 54017 Heat shield
(part of 9G271)
(part of 9J280)
Fuel tube bundle retaining clip (part of 9J279) (9
11 -
required)
12 9J279 Fuel tube
14 9J279 Vapor tube
(part of 9J279)
3.0L Vehicles 4593

WARNING: Do not carry personal electres such as cell phones, pagers or audio equipment of any
type when working on or near any fuel-related component. Highly flammable mixtures are always
All vehicles
100-02 .
3.5L vehicles
5. NOTE: The lower cowl panel must be removed to access the fuel and vapor tube quick connect
couplings.
Remove the lower cowl panel. For additional information, refer to the Cowl Panel Grille procedure in
Section 501-02 .
All vehicles
6. Remove the 4 nuts and the 2 heat shields.
container.
to Section 310-00 .
3.5L Vehicles 4594

10. Remove the fuel tank. For additional information, refer to Fuel Tank - All Wheel Drive (AWD) in this
section.
aside.
Remove the bolt and position the LR parking brake cable assembly aside.
&nbs
3.5L Vehicles 4595

Lines Manual
Inertia Fuel Shutoff (IFS) Switch - 3.5L

1 9341 Inertia Fuel Shutoff (IFS) switch
2 W504148 IFS bolt (2 required)
3 14489A IFS switch electrical connector
4 5413200 RH front door scuff plate
1. Remove the RH front door scuff plate.
2. Disconnect the Inertia Fuel Shutoff (IFS) switch electrical connector.
3. NOTICE: Do not overtighten the fasteners or damage to the switch will occur.
Remove the 2 bolts and the IFS switch.
Inertia Fuel Shutoff (IFS) Switch - 3.5L 4596

p;


SECTION 310-01B: Fuel Tank and Lines - Hybrid
Workshop Manual
Material
Item Specification
Fill
Capacity
XO-5W20-QSP (US);
Premium Motor Oil
equivalent
Item Specification
Fuel tank capacity 66.24L (17.5 gal)

Fuel Pump (FP) ccess cover screws 2 - 18
Fuel tank filler pipe bracket bolt 7 - 62
Fuel tank filler pipe bracket nut 7 - 62
Fuel tank filler pipe heat shield nut 9 - 80
Fuel tank filler pipe hose clamp 4 - 35
Fuel tank strap bolt 40 30 -
LH rear parking brake cable assembly bracket bolt 23 17 -
Lower crossover support brace nut 76 56 -


SECTION 310-01B: Fuel Tank and Lines - 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid
Hybrid Workshop Manual
Fuel Tank and Lines
Fuel System
The fuel system consists of:
• a 2-speed Mechanical Returnless Fuel System (MRFS).

• a standard L-shaped fuel tank.
• an Easy Fuel TM (capless) fuel tank filler pipe assembly, which cannot be modified in any way.
• a Fuel Pump (FP) module containing:
• fuel, vapor anake tubes in an integrated bundle assembly attached to the underside of the vehicle by
retaining clips.
• a FP control module.
The vehicle is equipped with a FP shutoff feature that is initiated by theRestraints Control Module (RCM).
The FP control module receives an event notification signal from the RCM to disable the FP . The event
notification signal is sent on a dedicated circuit between the FP control module and the RCM . Should the
vehicle shut-off after a collision due to this feature, restart the vehicle by first turning the ignition to the OFF
position and then turn the ignition to the ON position. In some instances, the vehicle may not restart the first
time and may take an additional attempt.


Fuel Tank and Lines

Fuel Tank and Filler Pipe - Exploded View
Fuel Tank and Filler Pipe

1 W807011 Fuel Pump (FP) module access cover screw (4
required)
2 54111 FP module access cover
4 14A464 FP module electrical connector
5 - Fuel tube-to- FP module quick connect coupling
(part of 9J279)
6 9H307 FP module
7 9J279 Fuel tube
8 9276 FP module O-ring seal
9 9002 Fuel tank
10 - Fuel vapor tube assembly-to-fuel tank quick
connect coupling (part of 9A228)
recirculation tube quick connect coupling (part of
9A228)
Fuel Tank and Filler Pipe - Exploded View 4603


16 - Fuel tank filler pipe recirculation tube (part of
9034)
18 9K072
>Information
bezel
21 - Fuel tank filler pipe housing retainer (3 required)
(part of 27936)
Fuel Tank Supports and Shields

4 9A031 Fuel tank heat shield
6 9B328 Fuel tank heat shield clip (2 required)
12 5428371 LH splash shield
Fuel Tank and Filler Pipe 4604

Fuel Tank Supports and Shields 4605

Fuel Tank
Special Tool(s)
Powertrain Lift
ignited. Failure to follow these instructions may result erious personal injury.
100-02 .
Fuel Tank 4606

6. Remove the 4 nuts, 2 clips and release the heat shield from the fuel tank.

Fuel Tank 4607

Fuel Tank Filler Pipe
Special Tool(s)
Fuel Storage Tanker

ignited. Failure to follow these ructions may result in serious personal injury.
100-02 .
fuel tank inlet.
Fuel Tank Filler Pipe 4608

6. Remove the 3 rivets, 6 pin-type retainers and the LR wheel splash shield.
8. Remove the fuel tank filler pipe bracket nut.

9. Remove the fuel tank filler pipe bracket bolt.

13. NOTE: Some fuel may remain in the fuel tank filler pipe after the initial drain. Carefully drain any
residual fuel into a suitable container.
14. Remove the fuel tank filler pipe assembly from the vehicle.


Fuel Pump Module
Special Tool(s)
Fuel Storage Tanker


310-123
Material
Item Specification
Motorc® SAE 5W-20 Premium WSS-M2C930-A
or equivalent
under high pressure, even when thengine is not running. Failure to follow this instruction may result in
Fuel Pump Module 4611

Fuel Pump (FP) module flange.

7. Disconnect the FP module electrical connector.
Section 310-00 .
arm.
Completely remove the FP module from the fuel tank.



Fuel Level Sender

1 9H307 Fuel Pump (FP) module
2 9A299 Fuel level sender
3 - Fuel level sender electrical connector (part of 9A299)
NOTE: The fuel level sender is serviced as part of a kit (9A299).
1. Remove the Fuel Pump (FP) module. For additional information, refer to Fuel Pump Module in this
section.
2. Disconnect the fuel level sender electrical connector.
3. Depress the lock tab and slide the fuel level sender upwards and remove.


Fuel Lines

2 54017 Heat shield
6 - Vapor jumper tube-to-vapor
tube quick connect coupling
(part of 9G271)
8 Fuel jumper tube-to-fuel tube
9J280)
9 - Hybrid fuel tube bundle
shield (part of 9J279)
10 - Hybrid fuel tube bundle
shield pin-type retainer
(part of 9J279)
11 5884 Lower crossover support
brace
12 W580415 Lower crossover support
brace nut (4 required)
13 - Fuel tube bundle retaining
clip (part of 9J279) (9
required)
14 9J279 Fuel tube
15 - Fuel tube-to-Fuel Pump
(FP) module quick connect
16 9J279 Vapor tube
Fuel Lines 4616

17 - Vapor jumper tube-to-vapor

tube quick connect coupling
(part of 9J279)
19 - Vapor jumper
tube-to-Evaporative
Emission (EVAP) canister
quick connect coupling
(part of 9J279)
20 - Stone shield (part of
2A815)
21 2A815 LR parking brake cable
assembly
22 W505263 Rear parking brake cable
assembly bolt
on or near anymponent. Highly flammable mixtures are always present and may be ignited. Failure to
follow these instructions may result in serious personal injury.
100-02 .
4. Remove the 4 nuts and 2 heat shields.
5. Release the pin-type retainer and remove the hybrid fuel tube bundle shield.
container.
Fuel Lines 4617

to Section 310-00 .
8. If equipped, remove the 6 bolts and the underbody shield.

10. Remove the fuel tank. For additional information, refer to Fuel Tank in this section.
aside.
Remove the bolt, stone shield and position the LR parking brake cable assembly aside.
Fuel Lines 4618

Fuel Lines 4619

SECTION 310-02: Acceleration 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop
Control Manual
Accelerator pedal and 10 89
sensor assembly nuts
Fuel Lines 4620

Control Manual
Acceleration Control
The acceleration controls consist of an accelerator pedal and sensor assembly.
The engine management system electronically operates the accelerator of the engine in response to accelerator
pedal movements initiated by the driver. In the event of a system failure, the engine management system
provides a "limp home" mode which allows the vehicle to be driven with limited performance.
Acceleration Control 4621

Control Manual
Acceleration Control
Acceleration Control 4622

Control Manual
Accelerator Pedal and Bracket
2.5L, 2.5L Hybrid and 3.0L Vehicles

1 14A464 Accelerator pedal sensor electrical connector
2 9F836 Accelerator pedal and sensor assembly
3 W706131 Accelerator pedal and sensor assembly nut (2
required)
3.5L Vehicles

1 14A464 Accelerator pedal sensor electrical connector
2 9F836 Accelerator pedal and sensor assembly
3 W706131 Accelerator pedal and sensor assembly nut (2
required)
Accelerator Pedal and Bracket 4623

NOTE: The sport metallic accelerator pedal pad is not to be re-used. If the sport metallic accelerator pedal
pad is removed it should be discarded and replaced with a new sport metallic accelerator pedal pad.
1. Disconnect the accelerator pedal sensor electrical connector.
2. Remove the 2 nuts and the accelerator pedal and sensor assembly.
3.5L Vehicles 4624

Acronyms
2WD - 2-Wheel Drive
4WD - Four-Wheel Drive
A/C - Air Conditioning
ABS - Acrylonitrile Butadiene Styrene
ABS - Anti-Lock Brake System
ACCM - Air Conditioning Compressor Module
ACL - Air Cleaner
ACM - Audio Control Module
ACM - Audio Front Control Module
ALR - Automatic Locking Retractor
APIM - Accessory Protocol Interface Module
APP - Accelerator Pedal Position
ATC - Active Torque Coupling
ATF - Automatic Transmission Fluid
AWD - All-Wheel Drive
BCM - Body Control Module
BCM-HVTB - Battery Control Module - High Voltage Traction Battery
BEC - Bussed Electrical Center
BECM - Battery Energy Control Module
BJB - Battery Junction Box
BLIS® - Blind Spot Information System
BLISTM - Blind Spot Information System
BPP - Brake Pedal Position
BPSM - Battery Pack Sensor Module
BSIA - Brake Shift Interlock Actuator
BTS - Belt Tension Sensor
Acronyms 4625
CAN - Controller Area Network
CAN2 - Controller Area Network 2
CASS - Compressor Anti-Slugging Strategy
CCA - Cold Cranking Amps
CHT - Cylinder Head Temperature
CID - Cubic Inch Displacement
CIP - Consumer Interface Processor
CKP - Crankshaft Position
CMDTC - Continuous Memory Diagnostic Trouble Code
CMDTCs - Continuous Memory Diagnostic Trouble Codes
CMP - Camshaft Position
CMS - Catalyst Monitor Sensor
CPA - Connector Position Assurance
CPP - Clutch Pedal Position
CTA - Cross Traffic Alert
CVT - Continuously Variable Transaxle
D/A - Dual Action
DAMB - Direct Acting Mechanical Buckets
DATC - Dual Automatic Temperature Control
DC/DC - DC to DC Converter Control Module
DCSM - Dual Climate Controlled Seat Module
DDM - Driver Door Module
DERU - Drive Engine Run-Up
DLC - Data Link Connector
DMM - Digital Multimeter
DOHC - Dual Overhead Camshaft
DP - Dual Phase Steel
Acronyms 4626
DRL - Daytime Running Lamps
DRM - Digital Rights Management
DSM - Driver Seat Module
DSO - District Special Order
DSP - Digital Signal Processing
DTC - Diagnostic Trouble Code
DTE - Distance To Empty
EATC - Electronic Automatic Temperature Control
EBD - Electronic Brake Distribution
ECM - Engine Control Module
ECT - Engine Coolant Temperature
ECU - Electronic Control Unit
eCVT - Electronically Controlled Continuously Variable Transmission
EEPROM - Electrically Erasable Programmable Read-Only Memory
EGR - Exhaust Gas Recirculation
EI - Electronic Ignition
ELR - Emergency Locking Retractor
EMTC - Electronic Manual emperature Control
EONV - Engine Off Natural Vacuum
EOP - Engine Oil Pressure
EPAS - Electronic Power Assist Steering
EPC - Electronic Pressure Control
ESC - Electronic Stability Control
ESN - Electronic Serial Number
ETC - Electronic Throttle Control
EVA - Electronic Vibration Analyzer
EVAP - Evaporative Emission
Acronyms 4627
FC - Fan Control
FCIM - Front Controls Interface Module
FDIM - Front Display Interface Module
FEAD - Front End Accessory Drive
FET - Field-Effect Transistor
FF - Flexible Fuel
FP - Fuel Pump
FTP - Fuel Tank Pressure
FWD - Front Wheel Drive
GEM - Generic Electronic Module
GPS - Global Positioning System
GPSM - Global Positioning System Module
GTDI - Gasoline Turbocharged Direct Injection
GVW - Gross Vehicle Weight
GVWR - Gross Vehicle Weight Rating
HCM - Headlamp Control Module
HCM-2 - Headlamp Control Module 2
HCU - Hydraulic Control Unit
HEV - Hybrid Electric Vehicle
HID - High Intensity Discharge
HO2S - Heated Oxygen Sensor
HPAS - Hydraulic Power Assist Steering
HS-CAN - High Speed Controller Area Network
HSLA - High-Strength Low Alloy
HSS - High-Strength Steel
HVAC - Heating Ventilation Air Conditioning
HVTB - High Voltage Traction Battery
Acronyms 4628
IAT - Intake Air Temperature
IC - Instrument Cluster
IDS - Integrated Diagnostic System
IFS - Inertia Fuel Shutoff
IKT - Integrated Keyhead Transmitter
IKTs - Integrated Keyhead Transmitters
ILCM - Interior Lighting Control Module
IPC - Instrument Panel Cluster
IPM-A - Image Processing Module - A
ISC - Idle Speed Control
KAM - Keep Alive Memory
KOEO - Key ON Engine OFF
KOER - Key ON Engine Running
KS - Knock Sensor
LCD - Liquid Crystal Display
LPC - Line Pressure Control
MACS - Mobile Air Conditioning Society
MAF - Mass Air Flow
MAP - Manifold Absolute Pressure
MECS - Motor Electronics Cooling System
MFI - Multi-Port Fuel Injection
MIG - Metal Inert Gas
MIL - Malfunction Indicator Lamp
MRFS - Mechanical Returnless Fuel System
MS-CAN - Medium Speed Controller Area Network
MSS - Mode Select Switch
NERU - Neutral Engine Run-Up
Acronyms 4629
NOx - Nitrogen Oxides
NVM - Non-Volatile Memory
O/D - Overdrive
OASIS - On-Line Automotive Service Information System
OBD - On-Board Diagnostic
OCS - Occupant Classification Sensor
OCS - Occupant Classification System
OCSM - Occupant Classification System Module
OHC - Overhead Camshaft
ORVR - On-Board Refueling Vapor Recovery
OSS - Output Shaft Speed
OTIS - One-Touch Integrated Start
OWC - One-Way Clutch
PAD - Passenger Air Bag Deactivation
PAM - Parking Aid Module
PATS - Passive Anti-Theft System
PC/ED - Powertrain Control/Emissions Diagnosis
PCM - Powertrain Control Module
PDB - Power Distribution Box
PIN - Personal Identification Number
PMI - Programmable Module Installation
PSCM - Power Steering Control Module
PSP - Power Steering Pressure
PTS - Professional Technician Society
PTU - Power Transfer Unit
PVC - Polyvinyl Chloride
PWM - Pulse Width Modulated
Acronyms 4630
PWM - Pulse-Width Modulation
PZEV - Partial Zero Emissions Vehicle
RAM - Random Access Memory
RCM - Restraints Control Module
RCU - Rear Control Unit
RDU - Rear Drive Unit
READ - Rear End Accessory Drive
RFI - Radio Frequency Interference
RKE - Remote Keyless Entry
ROM - Read-Only Memory
ROW - Rest Of World
RSC® - Roll Stability Control
SDARS - Satellite Digital Audio Receiver System
SFI - Sequential Multi-Port Fuel Injection
SJB - Smart Junction Box
SMC - Sheet-Molded Composite
SOD-L - Side Obstacle Detection Control Module - Left
SOD-R - Side Obstacle Detection Control Module - Right
SRS - Supplemental Restraint System
SSA - Shift Solenoid A
SSB - Shift Solenoid B
SSC - Shift Solenoid C
SSD - Shift Solenoid D
SSE - Shift Solenoid E
SSF - Shift Solenoid F
SSPCC - Shift Solenoid Pressure Control C
SSPCD - Shift Solenoid Pressure Control D
Acronyms 4631
SSPCE - Shift Solenoid Pressure Control E
SSPCF - Shift Solenoid Pressure Control F
STRW - Squeeze-Type Resistance Spot Welding
TB - Throttle Body
TCC - Torque Converter Clutch
TCIL - Transmission Control Indicator Lamp
TCM - Transmission Control Module
TCS - Transmission Control Switch
TDC - Top Dead Center
TED - Thermo-Electric Device
TEDs - Thermo-Electric Devices
TFT - Transmission Fluid Temperature
TIC - Transmitter Identification Code
TICs - Transmitter Identification Codes
TP - Throttle Position
TPM - Tire Pressure Monitor
TPMS - Tire Pressure Monitoring System
TPO - Thermoplastic Olefin
TR - Transmission Range
TRIP - Transformation Induced Plasticity Steel
TSB - Technical Service Bulletin
TSBs - Technical Service Bulletins
TSS - Turbine Shaft Speed
TTS - Text-To-Speech
TXV - Thermostatic Expansion Valve
UHSS - Ultra High Strength Steel
USB - Universal Serial Bus
Acronyms 4632
VC - Vehicle Certification
VCM - Vehicle Communication Module
VCT - Variable Camshaft Timing
VFS - Variable Force Solenoid
VID - Vehicle Identification
VIN - Vehicle Identification Number
VIP - Vehicle Interface Processor
VSS - Vehicle Speed Sensor
WMI - World Manufacturer Identifier
WOT - Wide Open Throttle
Acronyms 4633
Alphabetical Index
4|5|A|B|C|D|E|F|G|H|I|J|K|L|M|N|O|P|Q|R|S|T|U|V|W
4
4X4 Control Module (REMOVAL AND INSTALLATION, Four Wheel Drive (4WD) Systems)
5
5th/6th Gear (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Manual Transaxle/Transmission)
A
A-Pillar Trim Panel (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Acceleration Control (DESCRIPTION AND OPERATION)
Acceleration Control (DIAGNOSIS AND TESTING)
Acceleration Control (Section Table of Contents)
Acceleration Control (SPECIFICATIONS)
Accelerator Pedal and Bracket (REMOVAL AND INSTALLATION, Acceleration Control)
Accessory Drive (DESCRIPTION AND OPERATION, Accessory Drive - 2.5L)
Accessory Drive (DESCRIPTION AND OPERATION, Accessory Drive - 3.0L (4V))
Accessory Drive (DESCRIPTION AND OPERATION, Accessory Drive - 3.5L)
Accessory Drive (DESCRIPTION AND OPERATION, Accessory Drive - Hybrid)
Accessory Drive (DIAGNOSIS AND TESTING, Accessory Drive - 2.5L)
Accessory Drive (DIAGNOSIS AND TESTsory Drive - 3.0L (4V))
Accessory Drive (DIAGNOSIS AND TESTING, Accessory Drive - 3.5L)
Accessory Drive (DIAGNOSIS AND TESTING, Accessory Drive - Hybrid)
Accessory Drive Belt (REMOVAL AND INSTALLATION, Accessory Drive - 2.5L)
Accessory Drive Belt (REMOVAL AND INSTALLATION, Accessory Drive - 3.0L (4V))
Accessory DriveOVAL AND INSTALLATION, Accessory Drive - 3.5L)
Alphabetical Index 4634

Accessory Drive Belt (REMOVAL AND INSTALLATION, Accessory Drive - Hybrid)
Accessory Drive Belt Idler Pulley (REMOVAL AND INSTALLATION, Accessory Drive - 2.5L)
Accessory Drive Belt Tensioner (REMOVAL AND INSTALLATION, Accessory Drive - 2.5L)
Accessory Drive Belt Tensioner (REMOVAL AND INSTALLATION, Accessory Drive - 3.0L (4V))
Accessory Drive Belt Tensioner (REMOVAL AND INSTALLATION, Accessory Drive - 3.5L)
Accessory Drive Belt Tensioner (REMOVAL AND INSTALLATION, Accessory Drive - Hybrid)
Accessory Drive - 2.5L (Section Table of Contents)
Accessory Drive - 2.5L (SPECIFICATIONS)
Accessory Drive - 3.0L (4V) (Section Table of Contents)
Accessory Drive - 3.0L (4V) (SPECIFICATIONS)
Accessory Drive - 3.5L (Section Table of Contents)
Accessory Drive - 3.5L (SPECIFICATIONS)
Accessory Drive - Hybrid (Section Table of Contents)
Accessory Drive - Hybrid (SPECIFICATIONS)
Accessory Protocol Interface Mo) (REMOVAL AND INSTALLATION, Information and Entertainment
Systems)
Accessory Protocol Interface Module (APIM) Programming (GENERAL PROCEDURES, Module

Configuration)
Accessory Protocol Interface Module (APIM) Software Level Check (GENERAL PROCEDURES,
Information and Entertainment Systems)
Adaptive Headlighting (DIAGNOSIS AND TESTING, Exterior Lighting)
Adhesives (DESCRIPTION AND OPERATION, Body Repairs)
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) (DESCRIPTION AND
OPERATION, Supplemental Restraint System)
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) (DIAGNOSIS AND TESTING,
Supplemental Restraint System)
Air Cleaner (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - 2.5L)
Air Cleaner (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - 3.0L (4V))
Air Cleaner (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - 3.5L)
Air Cleaner (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - Hybrid)
A 4635
Air Cleaner Outlet Pipe (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - 2.5L)
Air Cleaner Outlet Pipe (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - 3.0L
(4V))
Air Cleaner Outlet Pipe (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - 3.5L)
Air Cleane Pipe (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - Hybrid)
Air Conditioning (DESCRIPTION AND OPERATION, Climate Control)
Air Conditioning (A/C) Clutch Air Gap Adjustment (GENERAL PROCEDURES, Climate Control System -
General Information and Diagnostics)
Air Conditioning (A/C) Compressor - 2.5L (REMOVAL AND INSTALLATION, Climate Control)
Air Conditioning (A/C) Compressor - 3.0L, 3.5L (REMOVAL AND INSTALLATION, Climate Control)
Air Conditioning (A/C) Compressor - Hybrid (REMOVAL AND INSTALLATION, Climate Control)
Air Conditioning (A/C) Evaporator Discharge Air Temperature Sensor (REMOVAL AND INSTALLATION,
Climate Control)
Air Conditioning (A/C) Odor Treatment (GENERAL PROCEDURES, Climate Control System - General
Information and Diagnostics)
Air Conditioning (A/C) Pressure Relief Valve (REMOVAL AND INSTALLATION, Climate Control)
Air Conditioning (A/C) Pressure Transducer (REMOVAL AND INSTALLATION, Climate Control)
Air Conditioning (A/C) System Flushing (GENERAL PROCEDURES, Climate Control System - General
Air Conditioning (A/C) System Recovery, Evacuation and Charging (GENERAL PROCEDURES, Climate
Control System - General Information and Diagnostics)
Air Deflector (REMOVAL AND INSTALLATION, Roof Opening Panel)
Air Distribution and Filtering (DESCRIPTION AND OPERATION, Climate Control)
Alternating Current (AC) Powerpoint (REMOVAL AND INSTALLATION, High Voltage

Converter/Inverter)
Ambient Air Temperature Sensor (REMOVAL AND INSTALLATION, Climate Control)
Ambient Lighting Module (REMOVAL AND INSTALLATION, Interior Lighting)
Ambient Lighting Switch (REMOVAL AND INSTALLATION, Interior Lighting)
Antenna Cable - AM/FM (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Antenna Cable - Satellite Radio (REMOVAL AND INSTALLATION, Information and Entertainment
Systems)
A 4636
Antenna Module (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Antenna - AM/FM (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Antenna - AM/FM/Satellite Radio/Navigation (REMOVAL AND INSTALLATION, Information and

Entertainment Systems)
Antenna - Satellite Radio (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Anti-Lock Brake System (ABS) and Stability Control (Section Table of Contents)
Anti-Lock Brake System (ABS) and Stability Control (SPECIFICATIONS)
Anti-Lock Brake System (ABS) Module (REMOVAL AND INSTALLATION, Anti-Lock Brake System
(ABS) and Stability Control)
Anti-Lock Brake System (ABS) Module - Hybrid (REMOVAL AND INSTALLATION, Anti-Lock Brake
System (ABS) and Stability Control)
Anti-Lock Control (DESCRIPTION AND OPERATION, An-Lock Brake System (ABS) and Stability
Control)
Anti-Lock Control - Hybrid (DIAGNOSIS AND TESTING, Anti-Lock Brake System (ABS) and Stability
Control)
Anti-Lock Control - Non-Hybrid (DIAGNOSIS AND TESTING, Anti-Lock Brake System (ABS) and
Stability Control)
Anti-Theft (DESCRIPTION AND OPERATION, Anti-Theft - Passive Anti-Theft System (PATS))
Anti-Theft (DESCRIPTION AND OPERATION, Anti-Theft - Passive Anti-Theft System (PATS) - Hybrid)
Anti-Theft (DESCRIPTION AND OPERATION, Anti-Theft - Perimeter)
Anti-Theft (DIAGNOSIS AND TESTING, Anti-Theft - Passive Anti-Theft System (PATS))
Anti-Theft (DIAGNOSIS AND TESTING, Anti-Theft - Passive Anti-Theft System (PATS) - Hybrid)
Anti-Theft (DIAGNOSIS AND TESTING, Anti-Theft - Perimeter)
Anti-Theft Inhibit Switch - Luggage Compartment (REMOVAL AND INSTALLATION, Anti-Theft -

Perimeter)
Anti-Theft Security Access (GENERAL PROCEDURES, Anti-Theft - Passive Anti-Theft System (PATS))
Anti-Theft Security Access (GENERAL PROCEDURES, Anti-Theft - Passive Anti-Theft System (PATS) -
Hybrid)
Anti-Theft - Passive Anti-Theft System (PATS) (Section Table of Contents)
Anti-Theft - Passive Anti-Theft System (PATS) - Hybrid (Section Table of Contents)
Anti-Theft - Perimeter (Section Table of Contents)
A 4637
Applique - Luggage Compartment Lid (REMOVAL AND INSTALLATION, Exterior Trim and
Ornamentation)
Apply Components (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - Aisin AW21)
Audio Amplifier (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Audio Control Module (ACM) Self-Diagnostic Mode (GENERAL PROCEDURES, Information and
Audio Control Mod(ACM) - Fusion (REMOVAL AND INSTALLATION, Information and Entertainment
Systems)
Audio Control Module (ACM) - MKZ (REMOVAL AND INSTALLATION, Information and Entertainment
Systems)
Audio Digital Signal Processing (DSP) Module (REMOVAL AND INSTALLATION, Information and
Audio Input Jack (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Autolamps (DIAGNOSIS AND TESTING, Exterior Lighting)
Autolamps Time Delay Adjustment (GENERAL PROCEDURES, Exterior Lighting)
Autolock and Auto-Unlock Programming (GENERAL PROCEDURES, Handles, Locks, Latches and Entry
Systems)
Automatic Transaxle/Transmission External Controls - Aisin AW21/6F35 (Section Table of Contents)
Automatic Transaxle/Transmission External Controls - Aisin AW21/6F35 (SPECIFICATIONS)
Automatic Transaxle/Transmission External Controls - Hybrid (Section Table of Contents)
Automatic Transaxle/Transmission External Controls - Hybrid (SPECIFICATIONS)
Automatic Transaxle/Transmission - 6F35 (Section Table of Contents)
Automatic Transaxle/Transmission - 6F35 (SPECIFICATIONS)
Automatic Transaxle/Transmission - Aisin AW21 (Section Table of Contents)
Automatic Transaxle/Transmission - Aisin AW21 (SPECIFICATIONS)
Automatic Transaxle/Transmission - Electronically Controlled Continuously Variable Transmission (eCVT)

(SPECIFICATIONS)
Auxiliary Coolant Flow Pump (REMOVAL AND INSTALLATION, Climate Control)
Axle Assembly (REMOVAL AND INSTALLATION, Rear Drive Axle/Differential)
Azimuth System CheGENERAL PROCEDURES, Parking Aid)
A 4638
B
B-Pillar Trim Panel (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Balance Shaft Backlash (GENERAL PROCEDURES, Engine - 2.5L)
Balance Shaft Backlash (GENERAL PROCEDURES, Engine - 2.5L Hybrid)
Ballast (REMOVAL AND INSTALLATION, Exterior Lighting)
Battery (REMOVAL AND INSTALLATION, Battery, Mounting and Cables)
Battery and Battery Tray - Exploded View (REMOVAL AND INSTALLATION, Battery, Mounting and
Cables)
Battery and Cables (DESCRIPTION AND OPERATION, Battery, Mounting and Cables)
Battery Cables - 2.5L (REMOVAL AND INSTALLATION, Battery, Mounting and Cables)
Battery Disconnect (GENERAL PROCEDURES, Battery, Mounting and Cables)
Battery Energy Control Module (BECM) (REMOVAL AND INSTALLATION, High Voltage Traction
Battery)
Battery Pack Sensor Module (BPSM) (REMOVAL AND INSTALLATION, High Voltage Traction Battery)
Battery Tray (REMOVAL AND INSTALLATION, Battery, Mounting and Cables)
Battery, Mounting and Cables (Section Table of Contents)
Battery, Mounting and Cables (SPECIFICATIONS)
Bearing Inspection (GENERAL PROCEDURES, Engine System - General Information)
Belt-Minder® Deactivating/Activating (GENERAL PROCEDURES, Instrumentation, Message Center, and

Warning Chimes)
Beltline Moulding - Front Door (REMOVAL AND INSTALLATION, Exterior Trim and Ornamentation)
Beltline Moulding - Rear Door (REMOVAL AND INSTALLATION, Exterior Trim and Ornamentation)
Blind Spot Monitoring (DESCRIPTION AND OPERATION, Side And Rear Vision)
Blind Spot Monitoring (DIAGNOSIS AND TESTING, Side And Rear Vision)
Block Heater (REMOVAL AND INSTALLATION, Engine Cooling)
Block Heater (REMOVAL AND INSTALLATION, Engine Cooling - Hybrid)
Blower Motor (REMOVAL AND INSTALLATION, Climate Control)
B 4639
Blower Motor Resistor (REMOVAL AND INSTALLATION, Climate Control)
Blower Motor Speed Control (REMOVAL AND INSTALLATION, Climate Control)
Body (DESCRIPTION AND OPERATION, Body Repairs)
Body Closures (Section Table of Contents)
Body Closures (SPECIFICATIONS)
Body Repairs (Section Table of Contents)
Body Repairs (SPECIFICATIONS)
Body Sealer Types And Applications (DESCRIPTION AND OPERATION, Body System - General
Information)
Body System (DIAGNOSIS AND TESTING, Body System - General Information)
Body System - General Information (Section Table of Contents)
Body System - General Information (SPECIFICATIONS)
Brake Booster (DESCRIPTION AND OPERATION, Power Brake Actuation)
Brake Booster Travel Sensor - Hybrid (REMOVAL AND INSTALLATION, Power Brake Actuation)
Brake Booster Vacuum Sensor - Hybrid (REMOVAL AND INSTALLATION, Power Brake Actuation)
Brake Booster Vacuum Sensor - Non-Hybrid (REMOVAL AND INSTALLATION, Power Brake Actuation)
Brake Booster - Exploded View (REMOVAL AND INSTALLATION, Power Brake Actuation)
Brake Booster - Hybrid (REMOVAL AND INSTALLATION, Power Brake Actuation)
Brake Booster - Non-Hybrid (REMOVAL AND INSTALLATION, Power Brake Actuation)
Brake Caliper (REMOVAL AND INSTALLATION, Front Disc Brake)
Brake Caliper (REMOVAL AND INSTALLATION, Rear Disc Brake)
Brake Caliper Anchor Plate (REMOVAL AND INSTALLATION, Front Disc Brake)
Brake Disc (REMOVAL AND INSTALLATION, Front Disc Brake)
Brake Disc (REMOVAL AND INSTALLATION, Rear Disc Brake)
Brake Disc Machining (GENERAL PROCEDURES, Brake System - General Information)
Brake Disc Shield - All Wheel Drive (AWD) (REMOVAL AND INSTALLATION, Rear Disc Brake)
Brake Disc Shield - Front Wheel Drive (FWD) (REMOVAL AND INSTALLATION, Rear Disc Brake)
Brake Flexible Hose (REMOVAL AND INSTALLATION, Front Disc Brake)
B 4640
Brake Flexible Hose (REMOVAL AND INSTALLATION, Rear Disc Brake)
Brake Fluid Reservoir (REMOVAL AND INSTALLATION, Hydraulic Brake Actuation)
Brake Master Cylinder (REMOVAL AND INSTALLATION, Hydraulic Brake Actuation)
Brake Pads (REMOVAL AND INSTALLATION, Front Disc Brake)
Brake Pads (REMOVAL AND INSTALLATION, Rear Disc Brake)
Brake Pedal and Bracket - Hybrid (REMOVAL AND INSTALLATION, Hydraulic Brake Actuation)
Brake Pedal and Bracket - Non-Hybrid (REMOVAL AND INSTALLATION, Hydraulic Brake Actuation)
Brake Pedal Angle Sensor (REMOVAL AND INSTALLATION, Hydraulic Brake Actuation)
Brake Pressure Control Valve (REMOVAL AND INSTALLATION, Hydraulic Brake Actuation)
Brake Shift Interlock Override (GENERAL PROCEDURES, Automatic Transaxle/Transmission External

Controls - Aisin AW21/6F35)
Brake Shift Interlock Override (GENERAL PROCEDURES, Automatic Transaxle/Transmission External

Controls - Hybrid)
Brake System (DESCRIPTION AND OPERATION, Brake System - General Information)
Brake System Bleeding (GENERAL PROCEDURES, Brake System - General Information)
Brake System Inspection (GENERAL PROCEDURES, Brake System - General Information)
Brake System - General Information (Section Table of Contents)
Brake System - General Information (SPECIFICATIONS)
Brake Vacuum Pump (REMOVAL AND INSTALLATION, Power Brake Actuation)
Bumper Cover - Front (REMOVAL AND INSTALLATION, Bumpers)
Bumper Cover - Rear (REMOVAL AND INSTALLATION, Bumpers)
Bumper - Exploded View, Front (REMOVAL AND INSTALLATION, Bumpers)
Bumper - Exploded View, Rear (REMOVAL AND INSTALLATION, Bumpers)
Bumper - Front (REMOVAL AND INSTALLATION, Bumpers)
Bumper - Rear (REMOVAL AND INSTALLATION, Bumpers)
Bumpers (Section Table of Contents)
Bumpers (SPECIFICATIONS)
Bypass Tube (REMOVAL AND INSTALLATION, Engine Cooling - Hybrid)
B 4641
Bypass Tube - 2.5L (REMOVASTALLATION, Engine Cooling)
C
C-Pillar Trim Panel (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Cabin Air Filter (REMOVAL AND INSTALLATION, Climate Control)
Camber Adjustment - Rear (GENERAL PROCEDURES, Suspension System - General Information)
Camshaft (INSTALLATION, Engine - 3.5L)
Camshaft (REMOVAL, Engine - 3.5L)
Camshaft Bearing Journal Diameter (GENERAL PROCEDURES, Engine System - General Information)
Camshaft End Play - OHC Engines (GENERAL PROCEDURES, Engine System - General Information)
Camshaft Journal to Bearing Clearance - OHC Engines (GENERAL PROCEDURES, Engine System -
General Information)
Camshaft Lobe Lift (GENERAL PROCEDURES, Engine System - General Information)
Camshaft Phaser and Sprocket (IN-VEHICLE REPAIR, Engine - 2.5L)
Camshaft Phaser and Sprocket (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Camshaft Phaser and Sprocket (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Camshaft Position (CMP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 2.5L)
Camshaft Position (CMP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.0L
(4V))
Camshaft Position (CMP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.5L)
Camshaft Position (CMP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - Hybrid)
Camshaft Roller Follower (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Camshaft Runout (GENERAL PROCEDURES, Engine System - General Information)
Camshaft Surface Inspection (GENERAL PROCEDURES, Engine System - General Information)
Camshafts (IN-VEHICLE REPAIR, Engine - 2.5L)
Camshafts (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Camshafts - LH (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Camshafts - RH (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
C 4642
Caster Adjustment - Front (GENERAL PROCEDURES, Suspension System - General Information)
Catalyst Monitor Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 2.5L)
Catalyst Monitor Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.0L (4V))
Catalyst Monitor Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.5L)
Catalyst Monitor Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - Hybrid)
Catalytic Converter - 3.0L LH Manifold (REMOVAL AND INSTALLATION, Exhaust System)
Catalytic Converter - 3.0L RH (REMOVAL AND INSTALLATION, Exhaust System)
Catalytic Converter - 3.5L LH (REMOVAL AND INSTALLATION, Exhaust System)
Catalytic Converter - 3.5L RH (REMOVAL AND INSTALLATION, Exhaust System)
Catalytic Converter - Manifold, Hybrid (REMOVAL AND INSTALLATION, Exhaust System)
Catalytic Converter - Underbody (REMOVTALLATION, Exhaust System)
Center Support (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic

Transaxle/Transmission - 6F35)
Charging System (DESCRIPTION AND OPERATION)
Charging System (Section Table of Contents)
Charging System (SPECIFICATIONS)
Child Safety Seat Tether Anchor (REMOVAL AND INSTALLATION, Safety Belt Stem)
Climate Control (Section Table of Contents)
Climate Control (SPECIFICATIONS)
Climate Control System (DESCRIPTION AND OPERATION, Climate Control System - General
Climate Control System (DESCRIPTION AND OPERATION, Climate Control System - General
Information and Diagnostics - Hybrid)
Climate Control System (DIAGNOSIS AND TESTING, Climate Control System - General Information and
Diagnostics - Hybrid)
Climate Control System - General Information and Diagnostics (Section Table of Contents)
Climate Control System - General Information and Diagnostics (SPECIFICATIONS)
Climate Control System - General Information and Diagnostics - Hybrid (Section Table of Contents)
Climate Control System - General Information and Diagnostics - Hybrid (SPECIFICATIONS)
C 4643
Clockspring (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Clutch (DESCRIPTION AND OPERATION)
Clutch (DIAGNOSIS AND TESTING)
Clutch (Section Table of Contents)
Clutch (SPECIFICATIONS)
Clutch and Clutch Field Coil (REMOVAL AND INSTALLATION, Climate Control)
Clutch Controls (DESCRIPTION AND OPERATION)
Clutch Controls (DIAGNOSIS AND TESTING)
Clutch Controls (Section Table of Contents)
Clutch Controls (SPECIFICATIONS)
Clutch Disc and Pressure Plate (REMOVAL AND INSTALLATION, Clutch)
Clutch Disc Check (GENERAL PROCEDURES, Manual Transaxle/Transmission and Clutch - General
Information)
Clutch Master Cylinder (REMOVAL AND INSTALLATION, Clutch Controls)
Clutch Pedal (REMOVAL AND INSTALLATION, Clutch Controls)
Clutch Pedal Freeplay Adjustment (GENERAL PROCEDURES, Manual Transaxle/Transmission and Clutch
- General Information)
Clutch Pedal Position (CPP) Switch (REMOVAL AND INSTALLATION, Electronic Engine Controls -
2.5L)
Clutch Pressure Plate Check (GENERAL PROCEDURES, Manual Transaxle/Transmission and Clutch -
Clutch Slave Cylinder (REMOVAL AND INSTALLATION, Clutch Controls)
Clutch Support Tower (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic

Clutch System Bleeding (GENERAL PROCEDURES, Manual Transaxle/Transmission and Clutch - General
Information)
Communications Network (DESCRIPTION AND OPERATION, Module Communications Network)
Communications Network (DIAGNOSIS AND TESTING, Module Communications Network)
Communications Network - Hybrid (DESCRIPTION AND OPERATION, Module Communications

Network)
Compass Calibration (GENERAL PROCEDURES, Instrumentation, Message Center, and Warning Chimes)
C 4644
Compass Zone Adjustment (GENERAL PROCEDURES, Instrumentation, Message Center, and Warning
Chimes)
Component Bleeding (GENERAL PROCEDURES, Brake System - General Information)
Component Test (DIAGNOSIS AND TESTING, Battery, Mounting and Cables)
Component Tests (DIAGNOSIS AND TESTING, Brake System - General Information)
Compressor Manifold and Tube Assembly - 2.MOVAL AND INSTALLATION, Climate Control)
Compressor Manifold and Tube Assembly - 3.0L, 3.5L (REMOVAL AND INSTALLATION, Climate
Control)
Compressor to Condenser Discharge Line - Hybrid (REMOVAL AND INSTALLATION, Climate Control)
Condenser Core - 2.5L, 3.0L, Hybrid (REMOVAL AND INSTALLATION, Climate Control)
Condenser Core - 3.5L (REMOVAL AND INSTALLATION, Climate Control)
Connecting Rod Bearing Journal Taper and Out-of-Round (GENERAL PROCEDURES, Engine System -
Connecting Rod Bearing Journal-to-Bearing Clearance (GENERAL PROCEDURES, Engine System -

Connecting Rod Bend (GENERAL PROCEDURES, Engine System - General Information)
Connecting Rod Bushing Diameter (GENERAL PROCEDURES, Engine System - General Information)
Connecting Rod Cleaning (GENERAL PROCEDURES, Engine System - General Information)
Connecting Rod Large End Bore (GENERAL PROCEDURES, Engine System - General Information)
Connecting Rod to Crankshaft Side Clearance (GENERAL PROCEDURES, Engine System - General
Information)
Connecting Rod Twist (GENERAL PROCEDURES, Engine System - General Information)
Console - Floor, Fusion (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Console - Floor, MKZ (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Console - Overhead (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Control Components (DESCRIPTION AND OPERATION, Climate Control)
Coolant Inlet Pipe - 3.0L (4V) (REMOVAL AND INSTALLATION, Engine Cooling)
Coolant Pump (REMOVAL AND INSTALLATION, Engine Cooling - Hybrid)
Coolant Pump Belt (REMOVAL AND INSTALLATION, Accessory Drive - 3.0L (4V))
Coolant Pump Housing - 3.0L (4V) (REMOVAL AND INSTALLATION, Engine Cooling)
C 4645
Coolant Pump - 2.5L (REMOVAL AND INSTALLATION, Engine Cooling)
Coolant Pump - 3.0L (4V) (REMOVAL AND INSTALLATION, Engine Cooling)
Coolant Pump - 3.5L (REMOVAL AND INSTALLATION, Engine Cooling)
Cooling Fan Motor and Shroud (REMOVAL AND INSTALLATION, Engine Cooling - Hyb
Cooling Fan Motor and Shroud - 2.5L, 3.0L (4V) (REMOVAL AND INSTALLATION, Engine Cooling)
Cooling Fan Motor and Shroud - 3.5L (REMOVAL AND INSTALLATION, Engine Cooling)
Cooling System Draining, Filling and Bleeding (GENERAL PROCEDURES, Engine Cooling)
Cooling System Draining, Filling and Bleeding (GENERAL PROCEDURES, Engine Cooling - Hybrid)
Cooling System Flushing (GENERAL PROCEDURES, Engine Cooling)
Cooling System Flushing (GENERAL PROCEDURES, Engine Cooling - Hybrid)
Core Plug Replacement (GENERAL PROCEDURES, Engine System - General Information)
Cover Seal (IN-VEHICLE REPAIR, Transfer Case - Power Transfer Unit (PTU))
Cowl Panel Grille (REMOVAL AND INSTALLATION, Front End Body Panels)
Crankcase Vent Oil Separator (REMOVAL AND INSTALLATION, Engine Emission Control - 2.5L)
Crankcase Vent Oil Separator (REMOVAL AND INSTALLATION, Engine Emission Control - Hybrid)
Crankshaft End Play (GENERAL PROCEDURES, Engine System - General Information)
Crankshaft Front Seal (IN-VEHICLE REPAIR, Engine - 2.5L)
Crankshaft Front Seal (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Crankshaft Front Seal (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Crankshaft Front Seal (IN-VEHICLE REPAIR, Engine - 3.5L)
Crankshaft Main Bearing Journal Diameter (GENERAL PROCEDURES, Engine System - General
Information)
Crankshaft Main Bearing Journal Taper and Out-of-Round (GENERAL PROCEDURES, Engine System -
Crankshaft Main Bearing Journal-to-Bearing Clearance (GENERAL PROCEDURES, Engine System -

Crankshaft Position (CKP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 2.5L)
Crankshaft Position (CKP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.0L
(4V))
C 4646
Crankshaft Position (CKP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.5L)
Crankshaft Position (CKP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls -
Hybrid)
Crankshaft Pulley (IN-VEHICLE REPAIR, Engine - 2.5L)
Crankshaft Pulley (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Crankshaft Pulley (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Crankshaft Pulley (IN-VEHICLE REPAIR, Engine - 3.5L)
Crankshaft Pulley and Crankshaft Front Seal - Exploded View (IN-VEHICLE REPAIR, Engine - 2.5L)
Crankshaft Pulley and Crankshaft Front Seal - Exploded View (IN-VEHICLE REPAIR, Eng Hybrid)
Crankshaft Pulley and Crankshaft Front Seal - Exploded View (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Crankshaft Pulley and Crankshaft Front Seal - Exploded View (IN-VEHICLE REPAIR, Engine - 3.5L)
Crankshaft Rear Seal (IN-VEHICLE REPAIR, Engine - 2.5L)
Crankshaft Rear Seal (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Crankshaft Rear Seal (IN-VEHICLE REPAIR, Engine - 3.5L)
Crankshaft Rear Seal with Retainer Plate (IN-VEHICLE REPAIR, Engine - 3.5L)
Cruise Control (DESCRIPTION AND OPERATION)
Cruise Control (DIAGNOSIS AND TESTING)
Cruise Control (Section Table of Contents)
Cruise Control Deactivator Switch (REMOVAL AND INSTALLATION, Cruise Control)
Cruise Control Switch (REMOVAL AND INSTALLATION, Cruise Control)
Cylinder Block Distortion (GENERAL PROCEDURES, Engine System - General Information)
Cylinder Bore Cleaning (GENERAL PROCEDURES, Engine System - General Information)
Cylinder Bore Out-of-RoundNERAL PROCEDURES, Engine System - General Information)
Cylinder Bore Taper (GENERAL PROCEDURES, Engine System - General Information)
Cylinder Head (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Engine - 2.5L)
Cylinder Head (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Engine - 2.5L Hybrid)
Cylinder Head (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Engine - 3.0L (4V))
Cylinder Head (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Engine - 3.5L)
C 4647
Cylinder Head (IN-VEHICLE REPAIR, Engine - 2.5L)
Cylinder Head (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Cylinder Head Distortion (GENERAL PROCEDURES, Engine System - General Information)
Cylinder Head Temperature (CHT) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls
- 2.5L)
- 3.0L (4V))
- 3.5L)
- Hybrid)
Cylinder Head - LH (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Cylinder Head - LH (INSTALLATION, Engine - 3.5L)
Cylinder Head - LH (REMOVAL, Engine - 3.5L)
Cylinder Head - RH (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Cylinder Head - RH (INSTALLATION, Engine - 3.5L)
Cylinder Head - RH (REMOVAL, Engine - 3.5L)
D
Daytime Running Lamps (DRL) (DIAGNOSIS AND TESTING, Exterior Lighting)
Degas Bottle (REMOVAL AND INSTALLATION, Engine Cooling)
Degas Bottle (REMOVAL AND INSTALLATION, Engine Cooling - Hybrid)
Diagnosis By Symptom (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6F35)
Diagnosis By Symptom (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Aisin AW21)
Diagnostic Flow Chart (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6F35)
Diagnostic Flow Chart (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Aisin AW21)
Diagnostic Methods (DESCRIPTION AND OPERATION, Service Information)
Diagnostic Parameters Identification (PID) Chart (DIAGNOSIS AND TESTING, Automatic

D 4648
Diagnostic Parameters Identification (PID) Chart (DIAGNOSIS AND TESTING, Automatic

Transaxle/Transmission - Aisin AW21)
Diagnostic Strategy (DIAGNOSIS AND TESTING, Automatic Tra/Transmission - 6F35)
Diagnostic Strategy (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Aisin AW21)
Diagnostic Trouble Code (DTC) Chart (DIAGNOSIS AND TESTING, Charging System)
Diagnostic Trouble Code (DTC) Chart (DIAGNOSIS AND TESTING, Exterior Lighting)
Diagnostic Trouble Code (DTC) Chart (DIAGNOSIS AND TESTING, Multifunction Electronic Modules)
Diagnostic Trouble Code (DTC) Charts (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission -
6F35)
Diagnostic Trouble Code (DTC) Charts (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission -
Aisin AW21)
Diagnostics (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6F35)
Diagnostics (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Aisin AW21)
Diagnostics (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Electronically Controlled

Continuously Variable Transmission (eCVT))
Differential (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Manual Transaxle/Transmission)
Differential Housing Cover (IN-VEHICLE REPAIR, Rear Drive Axle/Differential)
Differential Seals - LH (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - Aisin AW21)
Differential Seals - LH (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - Electronically

Controlled Continuously Variable Transmission (eCVT))
Differential Seals - RH (IN-VEHICLE REPAIic Transaxle/Transmission - Electronically Controlled

Continuously Variable Transmission (eCVT))
Differential Seals - RH, All Wheel Drive (AWD) (IN-VEHICLE REPAIR, Automatic
Differential Seals - RH, Front Wheel Drive (FWD) (IN-VEHICLE REPAIR, Automatic
Digital Transmission Range (TR) Sensor (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6F35)
Direct Current/Alternating Current (DC/AC) Inverter (REMOVAL AND INSTALLATION, High Voltage
Converter/Inverter)
Direct Current/Direct Current (DC/DC) Converter (REMOVAL AND INSTALLATION, High Voltage
Converter/Inverter)
Door (REMOVAL AND INSTALLATION, Body Closures)
D 4649
Door Alignment - Front (GENERAL PROCEDURES, Body Closures)
Door Alignment - Rear (GENERAL PROCEDURES, Body Closures)
Door Check Arm (REMOVAL AND INSTALLATION, Body Closures)
Door Glass Run and Bracket - Rear (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Door Glass Top Run - Front (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Door Handle Reinforcement - Exterior, Front (REMOVAL AND INSTALLATION, Handles, Locks, Latches
and Entry Systems)
Door Handle Reinforcement - Exterior, Rear (REMOVAL AND INSTALLATION, Handles, Locks, Latches
and Entry Systems)
Door Latch Release Cable (REMOVAL AND INSTALLATIONs, Locks, Latches and Entry Systems)
Door Lock Control Switch (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry
Systems)
Door Lock Cylinder (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Door Outer Panel (REMOVAL AND INSTALLATION, Body Repairs)
Door Trim Panel - Front (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Door Trim Panel - Rear (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Drive Pinion Seal (IN-VEHICLE REPAIR, Rear Drive Axle/Differential)
Driveline Angle Measurement (GENERAL PROCEDURES, Driveline System - General Information)
Driveline System (DESCRIPTION AND OPERATION, Driveline System - General Information)
Driveline System (DIAGNOSIS AND TESTING, Driveline System - General Information)
Driveline System - General Information (Section Table of Contents)
Driveline System - General Information (SPECIFICATIONS)
Driver Air Bag Module (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Driver Door Module (DDM) (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry
Systems)
Driver Seat Module (DSM) (REMOVAL AND INSTALLATION, Seating)
Driveshaft (DESCRIPTION AND OPERATION)
Driveshaft (DIAGNOSIS AND TESTING)
Driveshaft (REMOVAL AND INSTALLATION)
D 4650
Driveshaft (Section Table of Contents)
Driveshaft (SPECIFICATIONS)
Driveshaft Runout and Balancing (GENERAL PROCEDURES, Driveline System - General Information)
Dual Climate Controlled Seat Module (DCSM) (REMOVAL AND INSTALLATION, Seating)
E
Electronic Engine Controls (DESCRIPTION AND OPERATION, Electronic Engine Controls - 2.5L)
Electronic Engine Controls (DESCRIPTION AND OPERATION, Electronic Engine Controls - 3.0L (4V))
Electronic Engine Controls (DESCRIPTION AND OPERATION, Electronic Engine Controls - 3.5L)
Electronic Engine Controls (DESCRIPTION AND OPERATION, Electronic Engine Controls - Hybrid)
Electronic Engine Controls (DIAGNOSIS AND TESTING, Electronic Engine Controls - 2.5L)
Electronic Engine Controls (DIAGNOSIS AND TESTING, Electronic Engine Controls - 3.0L (4V))
Electronic Engine Controls (DIAGNOSIS AND TESTING, Electronic Engine Controls - 3.5L)
Electronic Engine Controls (DIAGNOSIS AND TESTING, Electronic Engine Controls - Hybrid)
Electronic Engine Controls - 2.5L (Section Table of Contents)
Electronic Engine Controls - 2.5L (SPECIFICATIONS)
Electronic Engine Controls - 3.0L (4V) (Section Table of Contents)
Electronic Engine Controls - 3.0L (4V) (SPECIFICATIONS)
Electronic Engine Controls - 3.5L (Section Table of Contents)
Electronic Engine Controls - 3.5L (SPECIFICATIONS)
Electronic Engine Controls - Hybrid (Section Table of Contents)
Electronic Engine Controls - Hybrid (SPECIFICATIONS)
Electronic Leak Detection (GENERAL PROCEDURES, Climate Control System - General Information and
Diagnostics)
Elevation System Check (GENERAL PROCEDURES, Parking Aid)
Engine (ASSEMBLY, Engine - 2.5L)
Engine (ASSEMBLY, Engine - 2.5L Hybrid)
Engine (ASSEMBLY, Engine - 3.0L (4V))
E 4651
Engine (ASSEMBLY, Engine - 3.5L)
Engine (DESCRIPTION AND OPERATION, Engine System - General Information)
Engine (DESCRIPTION AND OPERATION, Engine - 2.5L)
Engine (DESCRIPTION AND OPERATION, Engine - 2.5L Hybrid)
Engine (DESCRIPTION AND OPERATION, Engine - 3.0L (4V))
Engine (DESCRIPTION AND OPERATION, Engine - 3.5L)
Engine (DIAGNOSIS AND TESTING, Engine System - General Information)
Engine (DIAGNOSIS AND TESTING, Engine - 2.5L)
Engine (DIAGNOSIS AND TESTING, Engine - 2.5L Hybrid)
Engine (DIAGNOSIS AND TESTING, Engine - 3.0L (4V))
Engine (DIAGNOSIS AND TESTING, Engine - 3.5L)
Engine (DISASSEMBLY, Engine - 2.5L)
Engine (DISASSEMBLY, Engine - 2.5L Hybrid)
Engine (DISASSEMBLY, Engine - 3.0L (4V))
Engine (DISASSEMBLY, Engine - 3.5L)
Engine (INSTALLATION, Engine - 2.5L Hybrid)
Engine (INSTALLATION, Engine - 3.0L (4V))
Engine (INSTALLATION, Engine - 3.5L)
Engine (REMOVAL, Engine - 2.5L Hybrid)
Engine (REMOVAL, Engine - 3.0L (4V))
Engine (REMOVAL, Engine - 3.5L)
Engine Cooling (DESCRIPTION AND OPERATION)
Engine Cooling (DESCRIPTION AND OPERATION, Engine Cooling - Hybrid)
Engine Cooling (DIAGNOSIS AND TESTING)
Engine Cooling (DIAGNOSIS AND TESTING, Engine Cooling - Hybrid)
Engine Cooling (Section Table of Contents)
Engine Cooling (SPECIFICATIONS)
E 4652
Engine Cooling - Hybrid (Section Table of Contents)
Engine Cooling - Hybrid (SPECIFICATIONS)
Engine Emission Control (DESCRIPTION AND OPERATION, Engine Emission Control - 2.5L)
Engine Emission Control (DESCRIPTION AND OPERATION, Engine Emission Control - 3.0L (4V))
Engine Emission Control (DESCRIPTION AND OPERATION, Engine Emission Control - 3.5L)
Engine Emission Control (DESCRIPTION AND OPERATION, Engine Emission Control - Hybrid)
Engine Emission Control (DIAGNOSIS AND TESTING, Engine Emission Control - 2.5L)
Engine Emission Control (DIAGNOSIS AND TESTING, Engine Emission Control - 3.0L (4V))
Engine Emission Control (DIAGNOSIS AND TESTING, Engine Emission Control - 3.5L)
Engine Emission Control (DIAGNOSIS AND TESTING, Engine Emission Control - Hybrid)
Engine Emission Control - 2.5L (Section Table of Contents)
Engine Emission Control - 2.5L (SPECIFICATIONS)
Engine Emission Control - 3.0L (4V) (Section Table of Contents)
Engine Emission Control - 3.0L (4V) (SPECIFICATIONS)
Engine Emission Control - 3.5L (Section Table of Contents)
Engine Emission Control - 3.5L (SPECIFICATIONS)
Engine Emission Control - Hybrid (Section Table of Contents)
Engine Emission Control - Hybrid (SPECIFICATIONS)
Engine Front Cover (IN-VEHICLE REPAIR, Engine - 2.5L)
Engine Front Cover (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Engine Front Cover (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Engine Front Cover (INSTALLATION, Engine - 3.5L)
Engine Front Cover (REMOVAL, Engine - 3.5L)
Engine Ignition (DESCRIPTION AND OPERATION, Engine Ignition - 2.5L)
Engine Ignition (DESCRIPTION AND OPERATION, Engine Ignition - 3.0L (4V))
Engine Ignition (DESCRIPTION AND OPERATION, Engine Ignition - 3.5L)
Engine Ignition (DIAGNOSIS AND TESTING, Engine Ignition - 2.5L)
E 4653
Engine Ignition (DIAGNOSIS AND TESTING, Engine Ignition - 3.0L (4V))
Engine Ignition (DIAGNOSIS AND TESTING, Engine Ignition - 3.5L)
Engine Ignition Components - Exploded View (REMOVAL AND INSTALLATION, Engine Ignition - 2.5L)
Engine Ignition Components - Exploded View (REMOVAL AND INSTALLATION, Engine Ignition - 3.0L
(4V))
Engine Ignition Components - Exploded View (REMOVAL AND INSTALLATION, Engine Ignition - 3.5L)
Engine Ignition - 2.5L (Section Table of Contents)
Engine Ignition - 2.5L (SPECIFICATIONS)
Engine Ignition - 3.0L (4V) (Section Table of Contents)
Engine Ignition - 3.0L (4V) (SPECIFICATIONS)
Engine Ignition - 3.5L (Section Table of Contents)
Engine Ignition - 3.5L (SPECIFICATIONS)
Engine Lubrication Components - Exploded View (IN-VEHICLE REPAIR, Engine - 2.5L)
Engine Lubrication Components - Exploded View (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Engine Lubrication Components - Exploded View (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Engine Mount (IN-VEHICLE REPAIR, Engine - 2.5L)
Engine Mount (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Engine Mount (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Engine Mount (IN-VEHICLE REPAIR, Engine - 3.5L)
Engine Oil Pressure (EOP) Switch (IN-VEHICLE REPAIR, Engine - 2.5L)
Engine Oil Pressure (EOP) Switch (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Engine Oil Pressure (EOP) Switch (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Engine Oil Pressure (EOP) Switch (IN-VEHICLE REPAIR, Engine - 3.5L)
Engine System - General Information (Section Table of Contents)
Engine System - General Information (SPECIFICATIONS)
Engine - 2.5L (Section Table of Contents)
Engine - 2.5L (SPECIFICATIONS)
Engine - 2.5L Hybrid (Section Table of Contents)
E 4654
Engine - 2.5L Hybrid (SPECIFICATIONS)
Engine - 3.0L (4V) (Section Table of Contents)
Engine - 3.0L (4V) (SPECIFICATIONS)
Engine - 3.5L (Section Table of Contents)
Engine - 3.5L (SPECIFICATIONS)
Engine - Automatic Transaxle (INSTALLATION, Engine - 2.5L)
Engine - Automatic Transaxle (REMOVAL, Engine - 2.5L)
Engine - Manual Transaxle (INSTALLATION, Engine - 2.5L)="nospace">Engine - Manual Transaxle

(REMOVAL, Engine - 2.5L)
Evaporative Emission Canister (REMOVAL AND INSTALLATION, Evaporative Emissions)
Evaporative Emission Canister (REMOVAL AND INSTALLATION, Evaporative Emissions - Hybrid)
Evaporative Emission Canister Purge Valve (REMOVAL AND INSTALLATION, Evaporative Emissions)
Evaporative Emission Canistge Valve (REMOVAL AND INSTALLATION, Evaporative Emissions -

Hybrid)
Evaporative Emission System Leak Test (GENERAL PROCEDURES, Evaporative Emissions)
Evaporative Emission System Leak Test (GENERAL PROCEDURES, Evaporative Emissions - Hybrid)
Evaporative Emissions (DESCRIPTION AND OPERATION)
Evaporative Emissions (DESCRIPTION AND OPERATION, Evaporative Emissions - Hybrid)
Evaporative Emissions (DIAGNOSIS AND TESTING)
Evaporative Emissions (DIAGNOSIS AND TESTING, Evaporative Emissions - Hybrid)
Evaporative Emissions (Section Table of Contents)
Evaporative Emissions (SPECIFICATIONS)
Evaporative Emissions - Hybrid (Section Table of Contents)
Evaporator Core (REMOVAL AND INSTALLATION, Climate Control)
Evaporator to Compressor Suction Line - Hybrid (REMOVAL AND INSTALLATION, Climate Control)
Exhaust Flexible Pipe - 2.5L, 3.0L (REMOVAL AND INSTALLATION, Exhaust System)
Exhaust Gas Recirculation (EGR) System Components - Exploded View (REMOVAL AND
INSTALLATION, Engine Emission Control - 3.0L (4V))
Exhaust Gas Recirculation (EGR) Valve (REMOVAL AND INSTALLATION, Engine Emission Control -
E 4655
2.5L)
3.0L (4V))
Hybrid)
Exhaust Manifold (IN-VEHICLE REPAIR, Engine - 2.5L)
Exhaust Manifold Cleaning and Inspection (GENERAL PROCEDURES, Engine System - General
Information)
Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube (REMOVAL AND INSTALLATION,
Engine Emission Control - 3.0L (4V))
Exhaust Manifold - LH (IN-VEHICLE REPAIR, Engine - 3.5L)
Exhaust Manifold - RH (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Exhaust Manifold - RH (IN-VEHICLE REPAIR, Engine - 3.5L)
Exhaust System (DESCRIPTION AND OPERATION)
Exhaust System (DIAGNOSIS AND TESTING)
Exhaust System (Section Table of Contents)
Exhaust System (SPECIFICATIONS)
Exhaust System Alignment (GENERAL PROCEDURES, Exhaust System)
Exhaust System - Exploded View (REMOVAL AND INSTALLATION, Exhaust System)
Exhaust Y-Pipe - 3.5L (REMOVAL AND INSTALLATION, Exhaust System)
Exterior Door Handle (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Exterior Lighting (DESCRIPTION AND OPERATION)
Exterior Lighting (Section Table of Contents)
Exterior Lighting (SPECIFICATIONS)
Exterior Mirror (REMOVAL AND INSTALLATION, Rear View Mirrors)
Exterior Mirror Control Switch (REMOVAL AND INSTALLATION, Rear View Mirrors)
Exterior Mirror Cover (REMOVAL AND INSTALLATION, Rear View Mirrors)
Exterior Mirror Glass (REMOVAL AND INSTALLATION, Rear View Mirrors)
Exterior Mirror Motor (REMOVAL AND INSTALLATION, Rear View Mirrors)
E 4656
Exterior Mirrors - Exploded View (REMOVAL AND INSTALLATION, Rear View Mirrors)
Exterior Trim and Ornamentation (Section Table of Contents)
Exterior Trim and Ornamentation (SPECIFICATIONS)
External Controls (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission External

External Controls (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission External

Controls - Hybrid)
External Controls (DESCRIPTION AND OPERATION, Manual Transaxle/Transmission External Controls)
External Controls (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission External Controls -

Aisin AW21/6F35)
External Controls (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission External Controls -

Hybrid)
F
Fender (REMOVAL AND INSTALLATION, Front End Body Panels)
Fender Splash Shield (REMOVAL ANSTALLATION, Front End Body Panels)
Final Drive Carrier and Differential Assembly (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES,
Automatic Transaxle/Transmission - 6F35)
Flexplate (IN-VEHICLE REPAIR, Engine - 2.5L)
Flexplate (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Flexplate (IN-VEHICLE REPAIR, Engine - 3.5L)
Flexplate InspGENERAL PROCEDURES, Engine System - General Information)
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View (IN-VEHICLE REPAIR, Engine - 2.5L)
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View (IN-VEHICLE REPAIR, Engine - 2.5L
Hybrid)
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View (IN-VEHICLE REPAIR, Engine - 3.0L
(4V))
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View (IN-VEHICLE REPAIR, Engine - 3.5L)
Fluorescent Dye Leak Detection (GENERAL PROCEDURES, Climate Control System - General Information
and Diagnostics)
Flywheel (IN-VEHICLE REPAIR, Engine - 2.5L)
F 4657
Flywheel (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Flywheel Inspection (GENERAL PROCEDURES, Engine System - General Information)
Flywheel Runout Check (GENERAL PROCEDURES, Manual Transaxle/Transmission and Clutch - General
Information)
Fog Lamp (REMOVAL AND INSTALLATION, Exterior Lighting)
Fog Lamp Bulb (REMOVAL AND INSTALLATION, Exterior Lighting)
Fog Lamps (DIAGNOSIS AND TESTING, Exterior Lighting)
Four Wheel Drive (4WD) Systems (DESCRIPTION AND OPERATION)
Four Wheel Drive (4WD) Systems (DIAGNOSIS AND TESTING)
Four Wheel Drive (4WD) Systems (Section Table of Contents)
Four Wheel Drive (4WD) Systems (SPECIFICATIONS)
Frame Members - Front (REMOVAL AND INSTALLATION, Body Repairs)
Frame Members - Rear (REMOVAL AND INSTALLATION, Body Repairs)
Front Controls Interface Module (FCIM) - Fusion (REMOVAL AND INSTALLATION, Information and
Front Controls Interface Module (FCIM) - MKZ (REMOVAL AND INSTALLATION, Information and
Front Disc Brake (DESCRIPTION AND OPERATION)
Front Disc Brake (DIAGNOSIS AND TESTING)
Front Disc Brake (Section Table of Contents)
Front Disc Brake (SPECIFICATIONS)
Front Display Interface Module (FDIM) - Fusion (REMOVAL AND INSTALLATION, Information and
Front Display Interface Module (FDIM) - MKZ (REMOVAL AND INSTALLATION, Information and
Front Door Handles, Locks and Latches - Exploded View (REMOVAL AND INSTALLATION, Handles,
Locks, Latches and Entry Systems)
Front Door Latch (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Front Drive Halfshafts (DESCRIPTION AND OPERATION)
Front Drive Halfshafts (DIAGNOSIS AND TESTING)
F 4658
Front Drive Halfshafts (Section Table of Contents)
Front Drive Halfshafts (SPECIFICATIONS)
Front End Accessory Drive (FEAD) - Exploded View (REMOVAL AND INSTALLATION, Accessory Drive
- 2.5L)
- 3.0L (4V))
- 3.5L)
- Hybrid)
Front End Body Panels (Section Table of Contents)
Front End Body Panels (SPECIFICATIONS)
Front End Body Panels - Exploded View (REMOVAL AND INSTAront End Body Panels)
Front Fog Lamp Adjustment (GENERAL PROCEDURES, Exterior Lighting)
Front Impact Severity Sensor (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Front Suspension (DESCRIPTION AND OPERATION)
Front Suspension (DIAGNOSIS AND TESTING)
Front Suspension (Section Table of Contents)
Front Suspension (SPECIFICATIONS)
Fuel Charging and Controls (DESCRIPTION AND OPERATION, Fuel Charging and Controls - 2.5L)
Fuel Charging and Controls (DESCRIPTION AND OPERATION, Fuel Charging and Controls - 3.0L (4V))
Fuel Charging and Controls (DESCRIPTION AND OPERATION, Fuel Charging and Controls - 3.5L)
Fuel Charging and Controls (DTION AND OPERATION, Fuel Charging and Controls - Hybrid)
Fuel Charging and Controls (DIAGNOSIS AND TESTING, Fuel Charging and Controls - 2.5L)
Fuel Charging and Controls (DIAGNOSIS AND TESTING, Fuel Charging and Controls - 3.0L (4V))
Fuel Charging and Controls (DIAGNOSIS AND TESTING, Fuel Charging and Controls - 3.5L)
Fuel Charging and Controls (DIAGNOSIS AND TESTING, Fuel Charging and Controls - Hybrid)
Fuel Charging and Controls - 2.5L (Section Table of Contents)
Fuel Charging and Controls - 2.5L (SPECIFICATIONS)
F 4659
Fuel Charging and Controls - 3.0L (4V) (Section Table of Contents)
Fuel Charging and Controls - 3.0L (4V) (SPECIFICATIONS)
Fuel Charging and Controls - 3.5L (Section Table of Contents)
Fuel Charging and Controls - 3.5L (SPECIFICATIONS)
Fuel Charging and Controls - Hybrid (Section Table of Contents)
Fuel Charging and Controls - Hybrid (SPECIFICATIONS)
Fuel Injectors (REMOVAL AND INSTALLATION, Fuel Charging and Controls - 2.5L)
Fuel Injectors (REMOVAL AND INSTALLATION, Fuel Charging and Controls - 3.0L (4V))
Fuel Injectors (REMOVAL AND INSTALLATION, Fuel Charging and Controls - 3.5L)
Fuel Injectors (REMOVAL AND INSTALLATION, Fuel Charging and Controls - Hybrid)
Fuel Level Sender (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Fuel Level Sender (REMOVAL AND INSTALLATION, Fuel Tank and Lines - Hybrid)
Fuel Level Sensor (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Fuel Lines (REMOVAL AND INSTALLATION, Fuel Tank and Lines - Hybrid)
Fuel Lines - All Wheel Drive (AWD) (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Fuel Lines - Front Wheel Drive (FWD) (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Fuel Pump Control Module (REMOVAL AND INSTALLATION, Fuel Charging and Controls - 2.5L)
Fuel Pump Control Module (REMOVAL AND INSTALLATION, Fuel Charging and Controls - 3.0L (4V))
Fuel Pump Control Module (REMOVAL AND INSTALLATION, Fuel Charging and Controls - Hybrid)
Fuel Pump Module (REMOVAL AND INSTALLATION, Fuel Tank and Lines - Hybrid)
Fuel Pump Module - All Wheel Drive (AWD) (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Fuel Pump Module - Front Wheel Drive (FWD) (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Fuel Rail (REMOVAL AND INSTALLATION, Fuel Charging and Controls - 2.5L)
Fuel Rail (REMOVAL AND INSTALLATION, Fuel Charging and Controls - 3.0L (4V))
Fuel Rail (REMOVAL AND INSTALLATION, Fuel Charging and Controls - 3.5L)
Fuel Rail (REMOVAL AND INSTALLATION, Fuel Charging and Controls - Hybrid)
Fuel Rail and Fuel Injector - Exploded View (REMOVAL AND INSTALLATION, Fuel Charging and
Controls - 2.5L)
F 4660
Fuel Rail and Fuel Injector - Exploded View (REMOALLATION, Fuel Charging and Controls - 3.0L (4V))
Controls - 3.5L)
Controls - Hybrid)
Fuel System (DESCRIPTION AND OPERATION, Fuel System - General Information)
Fuel System (DIAGNOSIS AND TESTING, Fuel System - General Information)
Fuel System Pressure Release (GENERAL PROCEDURES, Fuel System - General Information)
Fuel System Pressure Test (GENERAL PROCEDURES, Fuel System - General Information)
Fuel System - General Information (Section Table of Contents)
Fuel System - General Information (SPECIFICATIONS)
Fuel Tank (REMOVAL AND INSTALLATION, Fuel Tank and Lines - Hybrid)
Fuel Tank and Filler Pipe - Exploded View (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Fuel Tank and Filler Pipe - Exploded View (REMOVAL AND INSTALLATION, Fuel Tank and Lines -
Hybrid)
Fuel Tank and Lines (DESCRIPTION AND OPERATION)
Fuel Tank and Lines (DESCRIPTION AND OPERATION, Fuel Tank and Lines - Hybrid)
Fuel Tank and Lines (DIAGNOSIS AND TESTING)
Fuel Tank and Lines (DIAGNOSIS AND TESTING, Fuel Tank and Lines - Hybrid)
Fuel Tank and Lines (Section Table of Contents)
Fuel Tank and Lines (SPECIFICATIONS)
Fuel Tank and Lines - Hybrid (Section Table of Contents)
Fuel Tank and Lines - Hybrid (SPECIFICATIONS)
Fuel Tank Draining - 2.5L (GENERAL PROCEDURES, Fuel System - General Information)
Fuel Tank Draining - 3.0L All Wheel Drive (AWD) (GENERAL PROCEDURES, Fuel System - General
Information)
Fuel Tank Draining - 3.0L Front Wheel Drive (FWD) (GENERAL PROCEDURES, Fuel System - General
Information)
Fuel Tank Draining - 3.5L (GENERAL PROCEDURES, Fuel System - General Information)
Fuel Tank Filler Pipe (REMOVAL AND INSTALLATION, Fuel Tank and Lines - Hybrid)
F 4661
Fuel Tank Filler Pipe - All Wheel Drive (AWD) (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Fuel Tank Filler Pipe - Front Wheel Drive (FWD) (REMOVAL AND INSTALLATION, Fuel Tank and
Lines)
Fuel Tank - All Wheel Drive (AWD) (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Fuel Tank - Front Wheel Drive (FWD) (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Fuel Vapor Tube Assembly (REMOVAL AND INSTALLATION, Evaporative Emissions - Hybrid)
Fuel Vapor Tube Assembly - All Wheel Drive (AWD) (REMOVAL AND INSTALLATION, Evaporative
Emissions)
Fuel Vapor Tube Assembly - Front Wheel Drive (FWD) (REMOVAL AND INSTALLATION, Evaporative
Emissions)
G
Gear Ratios (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6F35)
Gearshift Cable Adjustment (GENERAL PROCEDURES, Manual Transaxle/Transmission and Clutch -

Gearshift Cables (REMOVAL AND INSTALLATION, Manual Transaxle/Transmission External Controls)
Gearshift Lever (REMOVAL AND INSTALLATION, Manual Transaxle/Transmission External Controls)
Geartrain (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - Aisin AW21)
Generator - 2.5L (REMOVAL AND INSTALLATION, Charging System)
Glass Reseal - Rear (GENERAL PROCEDURES, Glass, Frames and Mechanisms)
Glass Reseal - Windshield (GENERAL PROCEDURES, Glass, Frames and Mechanisms)
Glass, Frames and Mechanisms (DESCRIPTION AND OPERATION)
Glass, Frames and Mechanisms (DIAGNOSIS AND TESTING)
Glass, Frames and Mechanisms (Section Table of Contents)
Glass, Frames and Mechanisms (SPECIFICATIONS)
Glass, Frames and Mechanisms - Exploded View, Front Door (REMOVAL AND INSTALLATION, Glass,
Frames and Mechanisms)
G 4662
Glass, Frames and Mechanisms - Exploded View, Rear Door (REMOVAL AND INSTALLATION, Glass,
Frames and Mechanisms)
Global Positioning System Module (GPSM) - Fusion (REMOVAL AND INSTALLATION, Information and
Global Positioning System Module (GPSM) - MKZ (REMOVAL AND INSTALLATION, Information and
H
Halfshaft (REMOVAL AND INSTALLATION, Front Drive Halfshafts)
Halfshaft (REMOVAL AND INSTALLATION, Rear Drive Halfshafts)
Halfshaft Seal (IN-VEHICLE REPAIR, Manual Transaxle/Transmission)
Halfshaft Seal - LH (IN-VEHICLE REP Automatic Transaxle/Transmission - 6F35)
Halfshaft Seal - RH, All Wheel Drive (AWD) (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission -
6F35)
Halfshaft Seal - RH, Front Wheel Drive (FWD) (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission
- 6F35)
Handles, Locks, Latches and Entry Systems (DESCRIPTION AND OPERATION)
Handles, Locks, Latches and Entry Systems (DIAGNOSIS AND TESTING)
Handles, Locks, Latches and Entry Systems (Section Table of Contents)
Handles, Locks, Latches and Entry Systems (SPECIFICATIONS)
Hazard Flasher Lamp Switch (REMOVAL AND INSTALLATION, Exterior Lighting)
Head Restraint Guide Sleeve (REMOVAL AND INSTALLATION, Seating)
Headlamp Adjustment (GENERAL PROCEDURES, Exterior Lighting)
Headlamp Assembly (REMOVAL AND INSTALLATION, Exterior Lighting)
Headlamp Bulb - LH, Fusion (REMOVAL AND INSTALLATION, Exterior Lighting)
Headlamp Bulb - LH, MKZ (REMOVAL AND INSTALLATION, Exterior Lighting)
Headlamp Bulb - RH, Fusion (REMOVAL AND INSTALLATION, Exterior Lighting)
Headlamp Bulb - RH, MKZ (REMOVAL AND INSTALLATION, Exterior Lighting)
Headlamp Control Module (HCM) (REMOVAL AND INSTALLATION, Exterior Lighting)
Headlamp Switch (REMOVAL AND INSTALLATION, Exterior Lighting)
H 4663
Headlamps (DIAGNOSIS AND TESTING, Exterior Lighting)
Headliner (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Heated Oxygen Sensor (HO2S) (REMOVAL AND INSTALLATION, Electronic Engine Controls - 2.5L)
Heated Oxygen Sensor (HO2S) (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.0L
(4V))
Heated Oxygen Sensor (HO2S) (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.5L)
Heated Oxygen Sensor (HO2S) (REMOVAL AND INSTALLATION, Electronic Engine Controls - Hybrid)
Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View (REMOVAL AND
INSTALLATION, Electronic Engine Controls - 2.5L)
INSTALLATION, Electronic Engine Controls - 3.0L (4V))lass="nospace">Heated Oxygen Sensor (HO2S)
and Catalyst Monitor Sensor - Exploded View (REMOVAL AND INSTALLATION, Electronic Engine
Controls - 3.5L)
INSTALLATION, Electronic Engine Controls - Hybrid)
Heated Seat Module (REMOVAL AND INSTALLATION, Seating)
Heated Seat Module Reset (GENERAL PROCEDURES, Seating)
Heater Core (REMOVAL AND INSTALLATION, Climate Control)
Heater Core And Evaporator Core Housing (REMOVAL AND INSTALLATION, Climate Control)
Heating and Ventilation (DESCRIPTION AND OPERATION, Climate Control)
Heating Ventilation Air Conditioning (HVAC) Module - Fusion, Milan (REMOVAL AND
INSTALLATION, Climate Control)
Heating Ventilation Air Conditioning (HVAC) Module - MKZ (REMOVAL AND INSTALLATION,
Climate Control)
High Mounted Stoplamp (REMOVAL AND INSTALLATION, Exterior Lighting)
High Voltage Converter/Inverter (Section Table of Contents)
High Voltage Converter/Inverter (SPECIFICATIONS)
High Voltage Traction Battery (Section Table of Contents)
High Voltage Traction Battery (SPECIFICATIONS)
High-Voltage Bussed Electrical Center (REMOVAL AND INSTALLATION, High Voltage Traction Battery)
High-Voltage Cables (REMOVAL AND INSTALLATION, High Voltage Traction Battery)
H 4664
High-Voltage Converter/Inverter (DESCRIPTION AND OPERATION, High Voltage Converter/Inverter)
High-Voltage Converter/Inverter (DIAGNOSIS AND TESTING, High Voltage Converter/Inverter)
High-Voltage Low-Current Fuse (REMOVAL AND INSTALLATION, High Voltage Traction Battery)
High-Voltage Traction Battery (DESCRIPTION AND OPERATION, High Voltage Traction Battery)
High-Voltage Traction Battery (DIAGNOSIS AND TESTING, High Voltage Traction Battery)
High-Voltage Traction Battery (REMOVAL AND INSTALLATION, High Voltage Traction Battery)
High-Voltage Traction Battery Connector and Bracket (REMOVAL AND INSTALLATION, High Voltage
Traction Battery)
High-Voltage Traction Battery Cooling Fan (REMOVAL AND INSTALLATION, High Voltage Traction
Battery)
High-Voltage Traction Battery Cooling Inlet Duct (REMOVAL AND INSTALLATION, High Voltage
Traction Battery)
High-Voltage Traction Battery Cooling Outlet Duct (REMOVAL AND INSTALLATION, High Voltage
Traction Battery)
High-Voltage Traction Battery Inlet Air Temperature Sensor (REMOVAL AND INSTALLATION, High
Voltage Traction Battery)
High-Voltage Traction Battery Systems Depowering (GENERAL PROCEDURES, High Voltage Traction
Battery)
Hood Latch (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Hood Latch Release Handle (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry
Systems)
Hood Latch Release Handle - Secondary (REMOVAL AND INSTALLATION, Handles, Locks, Latches and
Entry Systems)
Horn (DESCRIPTION AND OPERATION)
Horn (DIAGNOSIS AND TESTING)
Horn (REMOVAL AND INSTALLATION)
Horn (Section Table of Contents)
Horn (SPECIFICATIONS)
Hydraulic Brake Actuation (DESCRIPTION AND OPERATION)
Hydraulic Brake Actuation (DIAGNOSIS AND TESTING)
Hydraulic Brake Actuation (Section Table of Contents)
H 4665
Hydraulic Brake Actuation (SPECIFICATIONS)
Hydraulic Circuits (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6F35)
Hydraulic Control Unit (HCU) (REMOVAL AND INSTALLATION, Anti-Lock Brake System (ABS) and
Stability Control)
Hydraulic Control Unit (HCU) - Hybrid (REMOVAL AND INSTALLATION, Anti-Lock Brake System
(ABS) and Stability Control)
Hydraulic Lash Adjuster (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Hydraulic Lash Adjuster Inspection (GENERAL PROCEDURES, Engine System - General Information)
Hydraulic System (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6F35)
I
Identification Codes (DESCRIPTION AND OPERATION)
Identification Codes (Section Table of Contents)
Identification Tags (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6F35)
Identification Tags (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - Aisin AW21)
Ignition Coil-On-Plug (REMOVAL AND INSTALLATION, Engine Ignition - 2.5L)
Ignition Coil-On-Plug (REMOVAL AND INSTALLATION, Engine Ignition - 3.0L (4V))
Ignition Coil-On-Plug (REMOVAL AND INSTALLATION, Engine Ignition - 3.5L)
Ignition Lock Cylinder (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Ignition Switch (REMOVAL AND INSTALLATION, Steering Column Switches)
In-Vehicle Temperature and Humidity Sensor - Hybrid (REMOVAL AND INSTALLATION, Climate
Control)
In-Vehicle Temperature Sensor - Fusion, Milan (REMOVAL AND INSTALLATION, Climate Control)
In-Vehicle Temperature Sensor - MKZ (REMOVAL AND INSTALLATION, Climntrol)
Inertia Fuel Shutoff (IFS) Switch - 3.5L (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Information and Entertainment System (DESCRIPTION AND OPERATION, Information and Entertainment
Systems)
Information and Entertainment System (DIAGNOSIS AND TESTING, Information and Entertainment
Systems)
Information and Entertainment Systems (Section Table of Contents)
I 4666
Information and Entertainment Systems (SPECIFICATIONS)
Information And Message Center (DESCRIPTION AND OPERATION, Instrumentation, Message Center,
and Warning Chimes)
Inner Body Reinforcing Panels (REMOVAL AND INSTALLATION, Body Repairs)
Input Shaft (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Manual Transaxle/Transmission)
Inspection and Repair After a Supplemental Restraint System (SRS) Deployment (GENERAL
PROCEDURES, Supplemental Restraint System)
Inspection And Verification (DIAGNOSIS AND TESTING, Battery, Mounting and Cables)
Inspection And Verification (DIAGNOSIS AND TESTING, Brake System - General Information)
Inspection And Verification (DIAGNOSIS AND TESTING, Charging System)
Instrument Cluster and Panel Illumination (DESCRIPTION AND OPERATION)
Instrument Cluster and Panel Illumination (DIAGNOSIS AND TESTING)
Instrument Cluster and Panel Illumination (Section Table of Contents)
Instrument Cluster Finish Panel - Fusion (REMOVAL AND INSTALLATION, Instrument Panel and
Console)
Instrument Cluster Finish Panel - MKZ (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Instrument Panel (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Instrument Panel and Console (Section Table of Contents)
Instrument Panel and Console (SPECIFICATIONS)
Instrument Panel Cluster (IPC) (DESCRIPTION AND OPERATION, Instrumentation, Message Center, and
Warning Chimes)
Instrument Panel Cluster (IPC) (REMOVAL AND INSTALLATION, Instrumentation, Message Center, and
Warning Chimes)
Instrument Panel Dimmer Switch (REMOVAL AND INSTALLATION, Instrument Cluster and Panel
Illumination)
Instrument Panel Finish Panel - Center (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Instrument Panel Upper Section (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Instrument Panel - Exploded View (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Instrumentation, Message Center and Warning Chimes (DIAGNOSIS AND TESTING, Instrumentation,
Message Center, and Warning Chimes)
Instrumentation, Message Center, and Warning Chimes (Section Table of Contents)
I 4667
Insulation (DESCRIPTION AND OPERATION, Body System - General Information)
Intake Air Distribution and Filtering (DESCRIPTION AND OPERATION, Intake Air Distribution and
Filtering - 2.5L)
Filtering - 3.0L (4V))
Filtering - 3.5L)
Intake Air Distribution and Filtering (DESCRIPTION AND OPERATION, Intake Air Distribution and Fi-
Hybrid)
Intake Air Distribution and Filtering (DIAGNOSIS AND TESTING, Intake Air Distribution and Filtering -
2.5L)
3.0L (4V))
3.5L)
Hybrid)
Intake Air Distribution and Filtering - 2.5L (Section Table of Contents)
Intake Air Distribution and Filtering - 2.5L (SPECIFICATIONS)
Intake Air Distribution and Filtering - 3.0L (4V) (Section Table of Contents)
Intake Air Distribution and Filtering - 3.0L (4V) (SPECIFICATIONS)
Intake Air Distribution and Filtering - 3.5L (Section Table of Contents)
Intake Air Distribution and Filtering - 3.5L (SPECIFICATIONS)
Intake Air Distribution and Filtering - Hybrid (Section Table of Contents)
Intake Air Distribution and Filtering - Hybrid (SPECIFICATIONS)
Intake Air Resonator (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - 2.5L)
Intake Air Resonator (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - 3.0L (4V))
Intake Air Resonator (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - 3.5L)
Intake Air Resonator (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering - Hybrid)
Intake Air System Components - Exploded View (REMOVAL AND INSTALLATION, Intake Air
Distribution and Filtering - 2.5L)
I 4668
Distribution and Filtering - 3.0L (4V))
Distribution and Filtering - Hybrid)
Intake Manifold (IN-VEHICLE REPAIR, Engine - 2.5L)
Intake Manifold (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment (GENERAL
PROCEDURES, Anti-Theft - Passive Anti-Theft System (PATS))
Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment (GENERAL
PROCEDURES, Anti-Theft - Passive Anti-Theft System (PATS) - Hybrid)
Interior Door Handle (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Interior Lamp - Front (REMOVAL AND INSTALLATION, Interior Lighting)
Interior Lamp - Rear (REMOVAL AND INSTALLATION, Interior Lighting)
Interior Lighting (DESCRIPTION AND OPERATION)
Interior Lighting (DIAGNOSIS AND TESTING)
Interior Lighting (Section Table of Contents)
Interior Lighting (SPECIFICATIONS)
Interior Lighting Control Module (ILCM) (REMOVAL AND INSTALLATION, Interior Lighting)
Interior Rear View Mirror (REMOVAL AND INSTALLATION, Rear View Mirrors)
Interior Trim and Ornamentation (Section Table of Contents)
Interior Trim and Ornamentation (SPECIFICATIONS)
Interior Trim - Exploded View (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Intermediate Servo (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - Aisin AW21)
Intermediate Shaft Seal Deflector (IN-VEHICLE REPAIR, Transfer Case - Power Transfer Unit (PTU))
Intermediate Shaft Seal - 6F35 (INSTALLATION, Transfer Case - Power Transfer Unit (PTU))
Intermediate Shaft Seal - 6F35 (REMOVAL, Transfer Case - Power Transfer Unit (PTU))
Intermediate Shaft - All Wheel Drive (AWD) (REMOVAL AND INSTALLATION, Front Drive Halfshafts)
Intermediate Shaft - Front Wheel Drive (FWD) (REMOVAL AND INSTALLATION, Front Drive
Halfshafts)
I 4669
J
Jacking and Lifting (DESCRIPTION AND OPERATION)
Jacking and Lifting (Section Table of Contents)
K
Key Programming Switch State Control (GENERAL PROCEDURES, Anti-Theft - Passive Anti-Theft
System (PATS))
Key Programming Switch State Control (GENERAL PROCEDURES, Anti-Theft - Passive Anti-Theft
System (PATS) - Hybrid)
Key Programming Using Two Programmed Keys (GENERAL PROCEDURES, Anti-Theft - Passive
Anti-Theft System (PATS))
Key Programming Using Two Programmed Keys (GENERAL PROCEDURES, Anti-Theft - Passive
Anti-Theft System (PATS) - Hybrid)
Keyless Entry Keypad (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Keyless Entry Keypad Code Programming (GENERAL PROCEDURES, Handles, Locks, Latches and Entry
Systems)
Knee Air Bag Module (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Knock Sensor (KS) (REMOVAL AND INSTALLATION, Electronic Engine Controls - 2.5L) Knock Sensor
(KS) (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.0L (4V))
Knock Sensor (KS) (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.5L)
Knock Sensor (KS) (REMOVAL AND INSTALLATION, Electronic Engine Controls - Hybrid)
L
Latch Lubrication (GENERAL PROCEDURES, Handles, Locks, Latches and Entry Systems)
Lead Terminal Repair (GENERAL PROCEDURES, Glass, Frames and Mechanisms)
Leakage Inspection (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6F35)
Leakage Inspection (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Aisin AW21)
Light Sensor (REMOVAL AND INSTALLATION, Exterior Lighting)
Low One-Way Clutch (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic

Lower Arm (REMOVAL AND INSTALLATION, Rear Suspension)
J 4670
Lower Arm - Front (REMOVAL AND INSTALLATION, Front Suspension)
Lower Arm - Rear (REMOVAL AND INSTALLATION, Front Suspension)
Lower Intake Manifold (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Lower Intake Manifold (IN-VEHICLE REPAIR, Engine - 3.5L)
Luggage Compartment Lid (REMOVAL AND INSTALLATION, Body Closures)
Luggage Compartment Lid Alignment (GENERAL PROCEDURES, Body Closures)
Luggage Compartment Lid Latch (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry
Systems)
Luggage Compartment Lid Lock Cylinder (REMOVAL AND INSTALLATION, Handles, Locks, Latches
and Entry Systems)
Luggage Compartment Lid Release Switch (REMOVAL AND INSTALLATION, Handles, Locks, Latches
and Entry Systems)
Lumbar Assembly (REMOVAL AND INSTALLATION, Seating)
M
Main Control Cover (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6F35)
Main Control Valve Body (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic

Main Control Valve Body (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6F35)
Main Control Valve Body (IN-VEHICLE REPAIR, Automatic Transaxnsmission - Aisin AW21)
Maintenance Schedule (Section Table of Contents)
Maintenance Schedules - Gasoline Engines (DESCRIPTION AND OPERATION, Maintenance Schedule)
Maintenance Schedules - Hybrid (DESCRIPTION AND OPERATION, Maintenance Schedule)
Major Components (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6F35)
Manifold Absolute Pressure (MAP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls
- 2.5L)
- 3.0L (4V))
- Hybrid)
L 4671
Manual Control Lever Shaft and Seal (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - Aisin
AW21)
Manual Control Lever Shaft Seal (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6F35)
Manual Transaxle (DESCRIPTION AND OPERATION, Manual Transaxle/Transmission)
Manual Transaxle (DIAGNOSIS AND TESTING, Manual Transaxle/Transmission)
Manual Transaxle and Clutch (DESCRIPTION AND OPERATION, Manual Transaxle/Transmission and
Clutch - General Information)
Manual Transaxle and Clutch (DIAGNOSIS AND TESTING, Manual Transaxle/Transmission and Clutch -
Manual Transaxle/Transmission (Section Table of Contents)
Manual Transaxle/Transmission (SPECIFICATIONS)
Manual Transaxle/Transmission and Clutch - General Information (Section Table of Contents)
Manual Transaxle/Transmission and Clutch - General Information (SPECIFICATIONS)
Manual Transaxle/Transmission External Controls (Section Table of Contents)
Manual Transaxle/Transmission External Controls (SPECATIONS)
Mass Air Flow (MAF) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 2.5L)
Mass Air Flow (MAF) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.0L (4V))
Mass Air Flow (MAF) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.5L)
Mass Air Flow (MAF) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls - Hybrid)
Mechanical Components and Functions (DESCRIPTION AND OPERATION, Automatic

Memory Position Programming (GENERAL PROCEDURES, Seating)
Memory Set Switch (REMOVAL AND INSTALLATION, Seating)
Message Center Configuration (GENERAL PROCEDURES, Instrumentation, Message Center, and Warning
Chimes)
Microphone (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Mode Door Actuator - Air Inlet Door (REMOVAL AND INSTALLATION, Climate Control)
Mode Door Actuator - Defrost/Panel/Floor Door (REMOVAL AND INSTALLATION, Climate Control)
Module Communications Network (Section Table of Contents)
Module Configuration (DIAGNOSIS AND TESTING)
M 4672
Module Configuration (Section Table of Contents)
Module Controlled Functions (DESCRIPTION AND OPERATION, Multifunction Electronic Modules)
Motor Electronics Coolant Expansion Tank (REMOVAL AND INSTALLATION, Transaxle/Transmission

Cooling - Hybrid)
Motor Electronics Cooler (REMOVAL AND INSTALLATION, Transaxle/Transmission Cooling - Hybrid)
Motor Electronics Cooling System Draining and Filling (GENERAL PROCEDURES,

Transaxle/Transmission Cooling - Hybrid)
Motor Electronics Pump (REMOVAL AND INSTALLATION, Transaxle/Transmission Cooling - Hybrid)
Muffler and Tailpipe (REMOVAL AND INSTALLATION, Exhaust System)
Multifunction Electronic Modules (Section Table of Contents)
Multifunction Electronic Modules (SPECIFICATIONS)
MyKey® Programming (GENERAL PROCEDURES, Anti-Theft - Passive Anti-Theft System (PATS))
MyKey® Programming (GENERAL PROCEDURES, Anti-Theft - Passive Anti-Theft System (PATS) -

Hybrid)
MyKey® Restrictions on Vehicle Operation (DIAGNOSIS AND TESTING, Anti-Theft - Passive Anti-Theft
System (PATS))
MyKey® Restrictions on Vehicle Operation (DIAGNOSIS AND TESTING, Anti-Theft - Passive Anti-Theft
System (PATS) - Hybrid)
N
Neutral Position Learning (GENERAL PROCEDURES, Automatic Transaxle/Transmission - Aisin AW21)
Noise, Vibration and Harshness (Section Table of Contents)
Noise, Vibration and Harshness (NVH) (DESCRIPTION AND OPERATION, Noise, Vibration and
Harshness)
Noise, Vibration and Harshness (NVH) (DIAGNOSIS AND TESTING, Noise, Vibration and Harshness)
O
Occupant Classification Sensor (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Occupant Classification Sensor (OCS) System Reset (GENERAL PROCEDURES, Supplemental Restraint
System)
N 4673
Occupant Classification Sensor (OCS) System Zero Seat Weight Test (GENERAL PROCEDURES,
Occupant Classification System Module (OCSM) (REMOVAL AND INSTALLATION, Supplemental

Restraint System)
Oil Filter Adapter (IN-VEHICLE REPAIR, Engine - 2.5L)
Oil Filter Adapter (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Oil Filter Adapter (IN-VEHICLE REPAIR, Engine - 3.5L)
Oil Level Indicator and Tube (IN-VEHICLE REPAIR, Engine - 3.0
Oil Pan (IN-VEHICLE REPAIR, Engine - 2.5L)
Oil Pan (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Oil Pan (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Oil Pan (IN-VEHICLE REPAIR, Engine - 3.5L)
Oil Pan Baffle (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Oil Pump (IN-VEHICLE REPAIR, Engine - 2.5L)
Oil Pump (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Oil Pump (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Oil Pump (INSTALLATION, Engine - 3.5L)
Oil Pump (REMOVAL, Engine - 3.5L)
Oil Pump Screen and Pickup Tube (IN-VEHICLE REPAIR, Engine - 2.5L)
Oil Pump Screen and Pickup Tube (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Oil Pump Screen and Pickup Tube (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Oil Pump Screen and Pickup Tube (IN-VEHICLE REPAIR, Engine - 3.5L)
Output Shaft (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Manual Transaxle/Transmission)
Output Shaft Seal (IN-VEHICLE REPAIR, Transfer Case - Power Transfer Unit (PTU))
Output Shaft Speed (OSS) Sensor (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6F35)
Output State Control (OSC) Mode (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission -
6F35)
Overdrive/Direct Clutch Assembly (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic

O 4674
P
Parcel Shelf (REMOVAL AND INSTALLAterior Trim and Ornamentation)
Parking Aid (DESCRIPTION AND OPERATION)
Parking Aid (DIAGNOSIS AND TESTING)
Parking Aid (Section Table of Contents)
Parking Aid (SPECIFICATIONS)
Parking Aid Module (PAM) (REMOVAL AND INSTALLATION, Parking Aid)
Parking Aid Sensor (REMOVAL AND INSTALLATION, Parking Aid)
Parking Aid Speaker (REMOVAL AND INSTALLATION, Parking Aid)
Parking Aid - Video (DIAGNOSIS AND TESTING, Parking Aid)
Parking Brake (DESCRIPTION AND OPERATION, Parking Brake and Actuation)
Parking Brake (DIAGNOSIS AND TESTING, Parking Brake and Actuation)
Parking Brake and Actuation (SPECIFICATIONS)
Parking Brake Cable Adjustment (GENERAL PROCEDURES, Parking Brake and Actuation)
Parking Brake Cable - Rear (REMOVAL AND INSTALLATION, Parking Brake and Actuation)
Parking Brake Control (REMOVAL AND INSTALLATION, Parking Brake and Actuation)
Parking Brake Warning Indicator Switch (REMOVAL AND INSTALLATION, Parking Brake and
Actuation)
Parking Lamp Bulb - LH, Fusion (REMOVAL AND INSTALLATION, Exterior Lighting)
Parking Lamp Bulb - LH, MKZ (REMOVAL AND INSTALLATION, Exterior Lighting)
Parking Lamp Bulb - RH, Fusion (REMOVAL AND INSTALLATION, Exterior Lighting)
Parking Lamp Bulb - RH, MKZ (REMOVAL AND INSTALLATION, Exterior Lightin
Parking, Rear and License Plate Lamps (DIAGNOSIS AND TESTING, Exterior Lighting)
Passenger Air Bag Deactivation (PAD) Indicator (REMOVAL AND INSTALLATION, Supplemental
Restraint System)
Passenger Air Bag Module (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Passive Anti-Theft System (PATS) Parameter Reset (GENERAL PROCEDURES, Anti-Theft - Passive
P 4675
Passive Anti-Theft System (PATS) Parameter Reset (GENERAL PROCEDURES, Anti-Theft - Passive
Passive Anti-Theft System (PATS) Transceiver (REMOVAL AND INSTALLATION, Anti-Theft - Passive
Passive Anti-Theft System (PATS) Transceiver (REMOVAL AND INSTALLATION, Anti-Theft - Passive
Pilot Bearing (REMOVAL AND INSTALLATION, Clutch)
Pinpoint Test (DIAGNOSIS AND TESTING, Battery, Mounting and Cables)
Pinpoint Test (DIAGNOSIS AND TESTING, Charging System)
Pinpoint Tests (DIAGNOSIS AND TESTING, Brake System - General Information)
Pinpoint Tests - OSC Equipped Vehicle (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission -
6F35)
Pinpoint Tests - OSC Equipped Vehicle (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission -
Aisin AW21)
Piston (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Engine - 2.5L)
Piston (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Engine - 2.5L Hybrid)
Piston (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Engine - 3.0L (4V))
Piston (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Engine - 3.5L)
Piston Diameter (GENERAL PROCEDURES, Engine System - General Information)
Piston Inspection (GENERAL PROCEDURES, Engine System - General Information) Piston Pin Bore
Diameter (GENERAL PROCEDURES, Engine System - General Information)
Piston Pin Diameter (GENERAL PROCEDURES, Engine System - General Information)
Piston Ring End Gap (GENERAL PROCEDURES, Engine System - General Information)
Piston Ring-to-Groove Clearance (GENERAL PROCEDURES, Engine System - General Information)
Piston S (GENERAL PROCEDURES, Engine System - General Information)
Piston To Cylinder Bore Clearance (GENERAL PROCEDURES, Engine System - General Information)
Planetary Gearsets And Chain Drive Parts (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES,
Automatic Transaxle/Transmission - 6F35)
Plastic Components (DESCRIPTION AND OPERATION, Body Repairs)
Plastics Identification (GENERAL PROCEDURES, Body Repairs)
Plastics Refinishing (GENERAL PROCEDURES, Body Repairs)
P 4676
Plastics Repair (GENERAL PROCEDURES, Body Repairs)
Positive Crankcase Ventilation (PCV) Valve (REMOVAL AND INSTALLATION, Engine Emission Control
- 3.0L (4V))
Positive Crankcase Ventilation (PCV) Valve (REMOVAL AND INSTALLATION, Engine Emission Control
- 3.5L)
Power Brake Actuation (Section Table of Contents)
Power Brake Actuation (SPECIFICATIONS)
Power Brake System (DIAGNOSIS AND TESTING, Power Brake Actuation)
Power Point (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Power Steering (DESCRIPTION AND OPERATION)
Power Steering (DIAGNOSIS AND TESTING)
Power Steering (Section Table of Contents)
Power Steering (SPECIFICATIONS)
Power Steering Fluid Cooler - 3.5L (REMOVAL AND INSTALLATION, Power Steering)
Power Steering Fluid Reservoir - 3.5L (REMOVAL AND INSTALLATION, Power Steering)
Power Steering Pump Belt (REMOVAL AND INSTALLATION, Accessory Drive - 3.5L)
Power Steering Pump to Steering Gear Pressure Line (REMOVAL AND INSTALLATION, Power Steering)
Power Steering Pump - 3.5L (REMOVAL AND INSTALLATION, Power Steering)
Power Steering System Filling (GENERAL PROCEDURES, Steering System - Hydraulic Power Assist
Steering (HPAS))
Power Steering System Flushing (GENERAL PROCEDURES, Steering System - Hydraulic Power Assist
Steering (HPAS))
Power Steering System Purging (GENERAL PROCEDURES, Steering System - Hydraulic Power Assist
Steering (HPAS))
Power Transfer Unit (PTU) (DESCRIPTION AND OPERATION, Transfer Case - Power Transfer Unit
(PTU))
Power Transfer Unit (PTU) (DIAGNOSIS AND TESTING, Transfer Case - Power Transfer Unit (PTU))
Power Transfer Unit (PTU) (INSTALLATION, Transfer Case - Power Transfer Unit (PTU))
Power Transfer Unit (PTU) (REMOVAL, Transfer Case - Power Transfer Unit (PTU))
Power Transfer Unit (PTU) Draining and Filling (GENERAL PROCEDURES, Transfer Case - Power
Transfer Unit (PTU)) ss="nospace">Powertrain Control Module (PCM) (REMOVAL AND
P 4677
INSTALLATION, Electronic Engine Controls - 2.5L)
Powertrain Control Module (PCM) (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.0L
(4V))
Powertrain Control Module (PCM) (REMOVAL AND INSTALLATION, Electronic Engine Controls - 3.5L)
Powertrain Control Module (PCM) (REMOVAL AND INSTALLATION, Electronic Engine Controls -
Hybrid)
Powertrain/Drivetrain Mount Neutralizing (GENERAL PROCEDURES, Engine System - General

Information)
Preliminary Inspection (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6F35)
Preliminary Inspection (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Aisin AW21)
Principles of Operation (DIAGNOSIS AND TESTING, Battery, Mounting and Cables)
Principles of Operation (DIAGNOSIS AND TESTING, Brake System - General Information)
Principles of Operation (DIAGNOSIS AND TESTING, Charging System)
Programmable Module Installation (PMI) (GENERAL PROCEDURES, Module Configuration)
Puddle Lamp (REMOVAL AND INSTALLATION, Exterior Lighting)
Pump and Filter Assembly (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic

Pyrotechnic Device Disposal (GENERAL PROCEDURES, Supplemental Restraint System)
Q
Quick Connect Coupling (GENERAL PROCEDURES, Fuel System - General Information)
R
Radiator (REMOVAL AND INSTALLATION, Engine Cooling - Hybrid)
Radiator Grille Support (REMOVAL AND INSTALLATION, Front End Body Panels)
Radiator Grille - Fusion (REMOVAL AND INSTALLATION, Exterior Trim and Ornamentation)
Radiator Grille - MKZ (REMOVASTALLATION, Exterior Trim and Ornamentation)
Radiator - 2.5L, 3.0L (4V) (REMOVAL AND INSTALLATION, Engine Cooling)
Radiator - 3.5L (REMOVAL AND INSTALLATION, Engine Cooling)
Q 4678
Rain Sensor (REMOVAL AND INSTALLATION, Wipers and Washers)
Rain Sensor Bracket (REMOVAL AND INSTALLATION, Wipers and Washers)
Range Selection (DESCRIP AND OPERATION, Automatic Transaxle/Transmission - Aisin AW21)
Rear Disc Brake (DESCRIPTION AND OPERATION)
Rear Disc Brake (DIAGNOSIS AND TESTING)
Rear Disc Brake (Section Table of Contents)
Rear Disc Brake (SPECIFICATIONS)
Rear Door Handles, Locks and Latches - Exploded View (REMOVAL AND INSTALLATION, Handles,
Lockstches and Entry Systems)
Rear Door Latch (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Rear Drive Axle and Differential (DESCRIPTION AND OPERATION, Rear Drive Axle/Differential)
Rear Drive Axle and Differential (DIAGNOSIS AND TESTING, Rear Drive Axle/Differential)
Rear Drive Axle/Differential (Section Table of Contents)
Rear Drive Axle/Differential (SPECIFICATIONS)
Rear Drive Halfshafts (DESCRIPTION AND OPERATION)
Rear Drive Halfshafts (DIAGNOSIS AND TESTING)
Rear Drive Halfshafts (Section Table of Contents)
Rear Drive Halfshafts (SPECIFICATIONS)
Rear Lamp Assembly (REMOVAL AND INSTALLATION, Exterior Lighting)
Rear Suspension (DESCRIPTION AND OPERATION)
Rear Suspension (DIAGNOSIS AND TESTING)
Rear Suspension (Section Table of Contents)
Rear Suspension (SPECIFICATIONS)
Rear View Mirrors (DESCRIPTION AND OPERATION)
Rear View Mirrors (Section Table of Contents)
Rear View Mirrors (SPECIFICATIONS)
Rear View Mirrors - Exterior (DIAGNOSIS AND TESTING, Rear View Mirrors)
Rear View Mirrors - Interior (DIAGNOSIS AND TESTING, Rear View Mirrors)
R 4679
Receiver Drier Cartridge (REMOVAL AND INSTALLATION, Climate Control)
Refinishing - Environmental Damage (GENERAL PROCEDURES, Body Repairs)
Refinishing - Manufacturing Damage (GENERAL PROCEDURES, Body Repairs)
Refrigerant Identification Testing (GENERAL PROCEDURES, Climate Control System - General

Refrigerant Oil Adding (GENERAL PROCEDURES, Climate Control System - General Information and
Diagnostics)
Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation (GENERAL
PROCEDimate Control System - General Information and Diagnostics)
Refrigerant System Tests (GENERAL PROCEDURES, Climate Control System - General Information and
Diagnostics)
Register - Center, Fusion/Milan (REMOVAL AND INSTALLATION, Climate Control)
Register - Center, MKZ (REMOVAL AND INSTALLATION, Climate Control)
Register - Driver and Passenger Side, Fusion/Milan (REMOVAL AND INSTALLATION, Climate Control)
Register - LH, MKZ (REMOVAL AND INSTALLATION, Climate Control)
Register - RH, MKZ (REMOVAL AND INSTALLATION, Climate Control)
Remote Convenience (Section Table of Contents)
Remote Convenience (SPECIFICATIONS)
Remote Keyless Entry (RKE) Transmitter Programming (GENERAL PROCEDURES, Handles, Locks,
Latches and Entry Systems)
Remote Memory Activation (GENERAL PROCEDURES, Handles, Locks, Latches and Entry Systems)
Remote Memory Deactivation (GENERAL PROCEDURES, Handles, Locks, Latches and Entry Systems)
Resonator - 3.5L (REMOVAL AND INSTALLATION, Exhaust System)
Restoring Corrosion Protection Following Repair (GENERAL PROCEDURES, Body Repairs)
Restraints Control Module (RCM) (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Reverse Idler Gear (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Manual

Transaxle/Transmission)
Reversing Lamp (REMOVAL AND INSTALLATION, Exterior Lighting)
Reversing Lamp Switch (REMOVAL AND INSTALLATION, Exterior Lighting)
Reversing Lamps (DIAGNOSIS AND TESTING, Exterior Lighting)
R 4680
Ride Height Measurement (GENERAL PROCEDURES, Suspension System - General Information)
Rivet Nut Replacement (GENERAL PROCEDURES, Supplemental Restraint System)
Road Testing Vehicle (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6F35)
Road Testing Vehicle (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Aisin AW21)
Rocker Panel Moulding (REMOVAL AND INSTALLATION, Exterior Trim and Ornamentation)
Roller Follower Inspection (GENERAL PROCEDURES, Engine System - General Information)
Roof Opening Panel (DESCRIPTION AND OPERATION)
Roof Opening Panel (DIAGNOSIS AND TESTING)
Roof Opening Panel (Section Table of Contents)
Roof Opening Panel (SPECIFICATIONS)
Roof Opening Panel Alignment (GENERAL PROCEDURES, Roof Opening Panel)
Roof Opening Panel Control Switch (REMOVAL AND INSTALLATION, Roof Opening Panel)
Roof Opening Panel Frame (REMOVAL AND INSTALLATION, Roof Opening Panel)
Roof Opening Panel Glass (REMOVAL AND INSTALLATION, Roof Opening Panel)
Roof Opening Panel Motor (REMOVAL AND INSTALLATION, Roof Opening Panel)
Roof Opening Panel Motor Initialization (GENERAL PROCEDURES, Roof Opening Panel)
Roof Opening Panel Shield (REMOVAL AND INSTALLATION, Roof Opening Panel)
Roof Opening Panel - Exploded View (REMOVAL AND INSTALLATION, Roof Opening Panel)
Roof Panel (REMOVAL AND INSTALLATION, Body Repairs)
Rubber Insulating Gloves Testing (GENERAL PROCEDURES, High Voltage Traction Battery)
S
Safety Belt Buckle - Front (REMOVAL AND INSTALLATIONfety Belt System)
Safety Belt Buckle - Rear (REMOVAL AND INSTALLATION, Safety Belt System)
Safety Belt Cleaning (GENERAL PROCEDURES, Safety Belt System)
Safety Belt Maintenance (GENERAL PROCEDURES, Safety Belt System)
Safety Belt Procedure After a Collision (GENERAL PROCEDURES, Safety Belt System)
S 4681
Safety Belt Retractor and Ptensioner (REMOVAL AND INSTALLATION, Safety Belt System)
Safety Belt Retractor - Rear, Center (REMOVAL AND INSTALLATION, Safety Belt System)
Safety Belt Retractor - Rear, Outboard (REMOVAL AND INSTALLATION, Safety Belt System)
Safety Belt Shoulder Height Adjuster (REMOVAL AND INSTALLATION, Safety Belt System)
Safety Belt System (DESCRIPTION AND OPERATION)
Safety Belt System (DIAGNOSIS AND TESTING)
Safety Belt System (Section Table of Contents)
Safety Belt System (SPECIFICATIONS)
Safety Belt Tongue Rotated on Belt (GENERAL PROCEDURES, Safety Belt System)
Safety Belt Twisted at the Safety Belt Guide (GENERAL PROCEDURES, Safety Belt System)
Safety Warnings (DESCRIPTION AND OPERATION, Service Information)
Scuff Plate Trim Panel - Front (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Scuff Plate Trim Panel - Front, Lighted Outer (REMOVAL AND INSTALLATION, Interior Trim and
Ornamentation)
Scuff Plate Trim Panel - Rear (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Sealers (DESCRIPTION AND OPERATION, Body Repairs)
Seat Armrest - Rear (REMOVAL AND INSTALLATION, Seating)
Seat Backrest Cover - Front (REMOVAL AND INSTALLATION, Seating)
Seat Backrest Cover - Rear, 40 Percent (REMOVAL AND INSTALLATION, Seating)
Seat Backrest Cover - Rear, 60 Percent (REMOVAL AND INSTALLATION, Seating)
Seat Backrest Latch - Rear (REMOVAL AND INSTALLATION, Seating)
Seat Backrest Thermo-Electric Device (REMOVAL AND INSTALLATION, Seating)
Seat Backrest - Front (DISASSEMBLY AND ASSEMBLY, Seating)
Seat Backrest - Front (REMOVAL AND INSTALLATION, Seating)
Seat Backrest - Rear (REMOVAL AND INSTALLATION, Seating)
Seat Backrest - Rear, 40 Percent (DISASSEMBLY AND ASSEMBLY, Seating)
Seat Backrest - Rear, 60 Percent (DISASSEMBLY AND ASSEMBLY, Seating)
Seat Bolster - Rear (REMOVAL AND INSTALLATION, Seating)
S 4682
Seat Control Switch (REMOVAL AND INSTALLATION, Seating)
Seat Cushion Cover - Front (REMOVAL AND INSTALLATION, Seating)
Seat Cushion Cover - Rear (REMOVAL AND INSTALLATION, Seating)
Seat Cushion Thermo-Electric Device (REMOVAL AND INSTALLATION, Seating)
Seat Cushion - Front (DISASSEMBLY AND ASSEMBLY, Seating)
Seat Cushion - Rear (REMOVAL AND INSTALLATION, Seating)
Seat Latch Adjustment - Rear (GENERAL PROCEDURES, Seating)
Seat Position Sensor (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Seat Recliner Motor (REMOVAL AND INSTALLATION, Seating)
Seat Track (REMOVAL AND INSTALLATION, Seating)
Seat - Exploded View, Front (REMOVAL AND INSTALLATION, Seating)
Seat - Exploded View, Rear (REMOVAL AND INSTALLATION, Seating)
Seat - Front (REMOVAL AND INSTALLATION, Seating)
Se(Section Table of Contents)
Seating (SPECIFICATIONS)
Seats (DESCRIPTION AND OPERATION, Seating)
Seats (DIAGNOSIS AND TESTING, Seating)
Sectioning Guidelines (GENERAL PROCEDURES, Body Repairs)
Selector Lever (REMOVAL AND INSTALLATION, Automatic Transaxle/Transmission External Controls -

Hybrid)
Selector Lever Bezel (REMOVAL AND INSTALLATION, Automatic Transaxle/Transmission External

Controls - Hybrid)
Selector Lever Bezel - Fusion (REMOVAL AND INSTALLATION, Automatic Transaxle/Transmission

External Controls - Aisin AW21/6F35)
Selector Lever Bezel - MKZ (REMOVAL AND INSTALLATION, Automatic Transaxle/Transmission

Selector Lever Cable (REMOVAL AND INSTALLATION, Automatic Transaxle/Transmission External

Selector Lever Cable (REMOVAL AND INSTALLATION, Automatic Transaxle/Transmission External

Controls - Hybrid)
S 4683
Selector Lever Cable Adjustment (GENERAL PROCEDURES, Automatic Transaxle/Transmission External

Controls - Hybrid)
Selector Lever Cable Adjustment - 6F35 (GENERAL PROCEDURES, Automatic Transaxle/Transmission

Selector Lever Cable Adjustment - Aisin AW21 (GENERAL PROCEDURES, Automatic

Transaxle/Transmission External Controls - Aisin AW21/6F35)
Selector Lever Knob (REMOVAL AND INSTALLATION, Automat/Transmission External Controls - Aisin
AW21/6F35)
Selector Lever Knob (REMOVAL AND INSTALLATION, Automatic Transaxle/Transmission External

Controls - Hybrid)
Selector Lever - Fusion (REMOVAL AND INSTALLATION, Automatic Transaxle/Transmission External

Selector Lever - MKZ (REMOVAL AND INSTALLATION, Automatic Transaxle/Transmission External

Service Information (Section Table of Contents)
Shift Patterns (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6F35)
Shift Patterns (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - Aisin AW21)
Shift Point Road Test (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6F35)
Shift Point Road Test (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Aisin AW21)
Shock Absorber (REMOVAL AND INSTALLATION, Rear Suspension)
Shock Absorber and Spring Assembly (DISASSEMBLY AND ASSEMBLY, Front Suspension)
Shock Absorber and Spring Assembly (REMOVAL AND INSTALLATION, Front Suspension)
Side Air Bag Module (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Side Air Curtain Module (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Side And Rear Vision (Section Table of Contents)
Side Impact Sensor - C-Pillar (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Side Impact Sensor - Front Door (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Side Marker Lamp - Front (REMOVAL AND INSTALLATION, Exterior Lighting)
Side Obstacle Detection (SOD) Module (REMOVAL AND INSTALLATION, Side And Rear Vision)
Smart Junction Box (SJB) (DIAGNOSIS AND TESTING, Multifunction Electronic M)
Smart Junction Box (SJB) (REMOVAL AND INSTALLATION, Multifunction Electronic Modules)
S 4684
Solenoid Body Assembly (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic

Solenoid Body Assembly (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6F35)
Solenoid Body Leadframe (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6F35)
Solenoid Body Strategy (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6F35)
Solenoids (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6F35)
Sound Deadeners and Insulators (DESCRIPTION AND OPERATION, Body Repairs)
Spare Key Programming - Unlimited Key Mode (GENERAL PROCEDURES, Anti-Theft - Passive
Spare Key Programming - Unlimited Key Mode (GENERAL PROCEDURES, Anti-Theft - Passive
Spare Key Programming - Using Diagnostic Equipment (GENERAL PROCEDURES, Anti-Theft - Passive
Spare Key Programming - Using Diagnostic Equipment (GENERAL PROCEDURES, Anti-Theft - Passive
Spark Plug Inspection (GENERAL PROCEDURES, Engine System - General Information)
Spark Plugs (REMOVAL AND INSTALLATION, Engine Ignition - 2.5L)
Spark Plugs (REMOVAL AND INSTALLATION, Engine Ignition - 3.0L (4V))
s~en~file=SCS37C06.HTM~gen~ref.HTM" target="rightside">Spark Plugs (REMOVAL AND

INSTALLATION, Engine Ignition - 3.5L)
Speaker - Door (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Speaker - Instrument Panel (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Speaker - Parcel Shelf (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Speaker - Quarter Panel (REMOVAL AATION, Information and Entertainment Systems)
Speaker - Subwoofer (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Special Testing Procedures (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6F35)
Special Testing Procedures (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Aisin

AW21)
Spoiler (REMOVAL AND INSTALLATION, Exterior Trim and Ornamentation)
Spring (REMOVAL AND INSTALLATION, Rear Suspension)
Spring Lock Couplings (GENERAL PROCEDURES, Fuel System - General Information)
S 4685
Sprockets (GENERAL PROCEDURES, Engine System - General Information)
Stabilizer Bar (REMOVAL AND INSTALLATION, Front Suspension)
Stabilizer Bar and Link (REMOVAL AND INSTALLATION, Rear Suspension)
Stabilizer Bar Bushing (REMOVAL AND INSTALLATION, Front Suspension)
Stabilizer Bar Link (REMOVAL AND INSTALLATION, Front Suspension)
Starter Motor - 2.5L (REMOVAL AND INSTALLATION, Starting System)
Starting System (DESCRIPTION AND OPERATION)
Starting System (DIAGNOSIS AND TESTING)
Starting System (Section Table of Contents)
Starting System (SPECIFICATIONS)
Steering Column (DESCRIPTION AND OPERATION)
Steering Column (DIAGNOSIS AND TESTING)
Steering Column (REMOVAL AND INSTALLATION)
Steering Column (Section Table of Contents)
Steering Column (SPECIFICATIONS)
Steering Column Lock Module (REMOVAL AND INSTALLATION, Steering Column Switches)
Steering Column Multifunction Switch (REMOVAL AND INSTALLATION, Steering Column Switches)
Steering Column Shroud (REMOVAL AND INSTALLATION, Steering Column)
Steering Column Switches (DESCRIPTION AND OPERATION)
Steering Column Switches (DIAGNOSIS AND TESTING)
Steering Column Switches (Section Table of Contents)
Steering Gear - 2.5L Hybrid and 3.0L All Wheel Drive (AWD) (REMOVAL AND INSTALLATION, Power
Steering)
Steering Gear - 2.5L Non-Hybrid and 3.0L Front Wheel Drive (FWD) (REMOVAL AND INSTALLATION,
Power Steering)
Steering Gear - 3.5L All Wheel Drive (AWD) (REMOVAL AND INSTALLATION, Power Steering)
S 4686
Steering Gear - 3.5L Front Wheel Drive (FWD) (REMOVAL AND INSTALLATION, Power Steering)
Steering System (DESCRIPTION AND OPERATION, Steering System - Electronic Power Assist Steering
(EPAS))
Steering System (DESCRIPTION AND OPERATION, Steering System - Hydraulic Power Assist Steering
(HPAS))
Steering System (DIAGNOSIS AND TESTING, Steering System - Electronic Power Assist Steering (EPAS))
Steering System (DIAGNOSIS AND TESTING, Steering System - Hydraulic Power Assist Steering (HPAS))
Steering System - Electronic Power Assist Steering (EPAS) (Section Table of Contents)
Steering System - Hydraulic Power Assist Steering (HPAS) (Section Table of Contents)
Steering System - Hydraulic Power Assist Steering (HPAS) (SPECIFICATIONS)
Steering Wheel (REMOVAL AND INSTALLATION, Steering Column)
Steering Wheel Bezel (REMOVAL AND INSTALLATION, Steering Column)
Steering Wheel Controls (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Steering Wheel Rotation Sensor (REMOVAL AND INSTALLATION, Anti-Lock Brake System (ABS) and
Stability Control)
Steering Wheel Wrap Bonding (GENERAL PROCEDURES, Steering Column)
Stepped Unlock Programming (GENERAL PROCEDURES, Handles, Locks, Latches and Entry Systems)
Stoplamp Switch (REMOVAL AND INSTALLATION, Exterior Lighting)
Stoplamps (DIAGNOSIS AND TESTING, Exterior Lighting)
Storage Compartment - Upper (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Striker Adjustment (GENERAL PROCEDURES, Body Closures)
Stub Shaft Seal (IN-VEHICLE REPAIR, Rear Drive Axle/Differential)
Subframe and Mounting Systems (DESCRIPTION AND OPERATION, Uni-Body, Subframe and Mounting
System)
Subframe - Front (REMOVAL AND INSTALLATION, Uni-Body, Subframe and Mounting System)
Subframe - Rear (REMOVAL AND INSTALLATION, Uni-Body, Subframe and Mounting System)
Subwoofer Amplifier (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Supplemental Restraint System (Section Table of Contents)
Supplemental Restraint System (SPECIFICATIONS)
S 4687
Supplemental Restraint System (SRS) Deactivation and Reactivation (GENERAL PROCEDURES,

Supplemental Restraint System (SRS) Depowering and Repowering (GENERAL PROCEDURES,

Suspension System (DIAGNOSIS AND TESTING, Suspension System - General Information)
Suspension System - General Information (Section Table of Contents)
Suspension System - General Information (SPECIFICATIONS)
Symbols Glossary (DESCRIPTION AND OPERATION, Service Information)
Symptom Chart (DIAGNOSIS AND TESTING, Brake System - General Information)
Symptom Chart (DIAGNOSIS AND TESTING, Charging System)
T
Temperature Blend Door Actuator - LH (REMOVAL AND INSTALLATION, Climate Control)
Temperature Blend Door Actuator - RH, Dual-Zone EATC (REMOVAL AND INSTALLATION, Climate
Control)
Thermostat Housing (REMOVAL AND INSTALLATION, Engine Cooling - Hybrid)
Thermostat Housing - 2.5L (REMOVAL AND INSTALLATION, Engine Cooling)
Thermostat Housing - 3.5L (REMOVAL AND INSTALLATION, Engine Cooling)
Thermostat - 3.0L (4V) (REMOVAL AND INSTALLATION, Engine Cooling)
Thermostat - 3.5L (REMOVAL AND INSTALLATION, Engine Cooling)
Thermostatic Expansion Valve (REMOVAL AND INSTALLATION, Climate Control)
Thermostatic Expansion Valve Manifold and Tube Assembly (REMOVAL AND INSTALLATION, Climate
Control)
Throttle Body (REMOVAL AND INSTALLATION, Fuel Charging and Controls - 2.5L)
Throttle Body (REMOVAL AND INSTALLATION, Fuel Charging and Controls - 3.0L (4V))
Throttle Body (REMOVAL AND INSTALLATION, Fuel Charging and Controls - 3.5L)
Throttle Body (REMOVAL AND INSTALLATION, Fuel Charging and Controls - Hybrid)
Tie Rod - Inner (REMOVAL AND INSTALLATION, Power Steering)
Timing Adjustment (GENERAL PROCEDURES, Roof Opening Panel)
T 4688
Timing Drive Components (IN-VEHICLE REPAIR, Engine - 2.5L)
Timing Drive Components (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Timing Drive Components (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Timing Drive Components (INSTALLATION, Engine - 3.5L)
Timing Drive Components (REMOVAL, Engine - 3.5L)
Tire Pressure Monitoring System (TPMS) (DIAGNOSIS AND TESTING, Wheels and Tires)
Tire Pressure Monitoring System (TPMS) Sensor (DISASSEMBLY AND ASSEMBLY OF

SUBASSEMBLIES, Wheels and Tires)
Tire Pressure Monitoring System (TPMS) Sensor Activation (GENERAL PROCEDURES, Wheels and Tires)
Tire Pressure Monitoring System (TPMS) Sensor Training (GENERAL PROCEDURES, Wheels and Tires)
Toe Adjustment - Front (GENERAL PROCEDURES, Suspension System - General Information)
Toe Adjustment - Rear (GENERAL PROCEDURES, Suspension System - General Information)
Toe Link (REMOVAL AND INSTALLATION, Rear Suspension)
Torca® Clamp (GENERAL PROCEDURES, Exhaust System)
SCS~us~en~file=SCS71B06.HTM~gen~ref.HTM" target="rightside">Torque Converter (DESCRIPTION

AND OPERATION, Automatic Transaxle/Transmission - 6F35)
Torque Converter (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - Aisin AW21)
Torque Converter (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic

Torque Converter Contamination Inspection (GENERAL PROCEDURES, Automatic

Torque Converter Contamination Inspection (GENERAL PROCEDURES, Automatic

Torque Converter Diagnosis (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6F35)
Torque Converter Diagnosis (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Aisin

AW21)
Torque Converter Hub Seal (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic

Traction Control Switch (REMOVAL AND INSTALLATION, Anti-Lock Brake System (ABS) and Stability
Control)
Trailing Arm (REMOVAL AND INSTALLATION, Rear Suspension)
T 4689
Transaxle (ASSEMBLY, Automatic Transaxle/Transmission - 6F35)
Transaxle (ASSEMBLY, Manual Transaxle/Transmission)
Transaxle (DISASSEMBLY, Automatic Transaxle/Transmission - 6F35)
Transaxle (DISASSEMBLY, Manual Transaxle/Transmission)
Transaxle (INSTALLATION, Automatic Transaxle/Transmission - Aisin AW21)
Transaxle (INSTALLATION, Automatic Transaxle/Transmission - Electronically Controlled Continuously

Variable Transmission (eCVT))
Transaxle (INSTALLATION, Manual Transaxle/Transmission)
Transaxle (REMOVAL, Automatic Transaxle/Transmission - Aisin AW21)
Transaxle (REMOVAL, Automatic Transaxle/Transmission - Electronically Controlled Continuously

Variable Transmission (eCVT))
Transaxle (REMOVAL, Manual Transaxle/Transmission)
Transaxle Case (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Manual

Transaxle/Transmission)
Transaxle Case Bushing (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6F35)
Transaxle Connector Layouts (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6F35)
Transaxle Connector Layouts (DIAGNOSIS AND TESTINGtomatic Transaxle/Transmission - Aisin AW21)
Transaxle Cooling (DESCRIPTION AND OPERATION, Transaxle/Transmission Cooling - Hybrid)
Transaxle Cooling (DIAGNOSIS AND TESTING, Transaxle/Transmission Cooling - Hybrid)
Transaxle Cooling - 6F35 (DESCRIPTION AND OPERATION, Transaxle/Transmission Cooling - Aisin

AW21/6F35)
Transaxle Cooling - 6F35 (DIAGNOSIS AND TESTING, Transaxle/Transmission Cooling - Aisin

AW21/6F35)
Transaxle Cooling - Aisin AW21 (DESCRIPTION AND OPERATION, Transaxle/Transmission Cooling -

Aisin AW21/6F35)
Transaxle Cooling - Aisin AW21 (DIAGNOSIS AND TESTING, Transaxle/Transmission Cooling - Aisin
AW21/6F35)
Transaxle Description (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6F35)
Transaxle Description (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - Aisin

AW21)
Transaxle Description (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission -

Electronically Controlled Continuously Variable Transmission (eCVT))
T 4690
Transaxle Draining and Filling (GENERAL PROCEDURES, Manual Transaxle/Transmission)
Transaxle Drive Cycle Test (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6F35)
Transaxle Drive Cycle Test (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Aisin
AW21)
Transaxle Electronic Control System (DESCRIPTION AND OPERATION, Automatic

Transaxle Electronic Control System (DESCRIPTION AND OPERATION, Automatic

Transaxle Filler Tube (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6F35)
Transaxle Operation (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6F35)
Transaxle Operational Strategies (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission -

Aisin AW21)
Transaxle Rear Support Insulator (IN-VEHICLE REPAIR, Manual Transaxle/Transmission)
Transaxle Support Insulator (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - Aisin AW21)
Transaxle Support Insulator (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - Electronically

Controlled Continuously Variable Transmission (eCVT))
Transaxle Support Insulator - 2.5L (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6F35)
Transaxle Support Insulator - 3.0L (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6F35)
Transaxle Support Insulator - Anti-Roll (IN-VEHIComatic Transaxle/Transmission - 6F35)
Transaxle Support Insulator - Anti-Roll (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission -

Transaxle - 2.5L (INSTALLATION, Automatic Transaxle/Transmission - 6F35)
Transaxle - 2.5L (REMOVAL, Automatic Transaxle/Transmission - 6F35)
Transaxle - 3.0L (INSTALLATION, Automatic Transaxle/Transmission - 6F35)
Transaxle - 3.0L (REMOVAL, Automatic Transaxle/Transmission - 6F35)
Transaxle/Transmission Cooling - Aisin AW21/6F35 (Section Table of Contents)
Transaxle/Transmission Cooling - Aisin AW21/6F35 (SPECIFICATIONS)
Transaxle/Transmission Cooling - Hybrid (Section Table of Contents)
Transaxle/Transmission Cooling - Hybrid (SPECIFICATIONS)
Transfer Case - Power Transfer Unit (PTU) (Section Table of Contents)
T 4691
Transfer Case - Power Transfer Unit (PTU) (SPECIFICATIONS)
Transmission Control Module (TCM) (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - Aisin

AW21)
Transmission Control Module (TCM) Initial Learning (GENERAL PROCEDURES, Automatic

Transmission Fluid Cooler (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6F35)
Transmission Fluid Cooler (REMOVAL AND INSTALLATION, Transaxle/Transmission Cooling - Aisin

AW21/6F35)
Transmission Fluid Cooler Backflushing and Cleaning (GENERAL PROCEDURES, Automatic

Transmission Fluid Cooler Tubes - 6F35 (REMOVAL AND INSTALLATION, Transaxle/Transmission

Cooling - Aisin AW21/6F35)
Transmission Fluid Cooler Tubes - Aisin AW21 (REMOVAL AND INSTALLATION,

Transaxle/Transmission Cooling - Aisin AW21/6F35)
Transmission Fluid Cooler - Backflushing and Cleaning (GENERAL PROCEDURES, Automatic

Transmission Fluid Drain and Refill (GENERAL PROCEDURES, Automatic Transaxle/Transmission -

6F35)
Transmission Fluid Drain and Refill (GENERAL PROCEDURES, Automatic Transaxle/Transmission - Aisin
AW21)
Transmission Fluid Drain and Refill (GENERAL PROCEDURES, Automatic Transaxle/Transmission -

Transmission Fluid Exchange (GENERAL PROCEDURES, Automatic Transaxle/Transmission - 6F35)
Transmission Fluid Exchange (GENERAL PROCEDURES, Automatic Transaxle/Transmission - Aisin

AW21)
Transmission Range (TR) Sensor (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission -

Trough Assembly (REMOVAL AND INSTALLATION, Roof Opening Panel)
Turbine Shaft Speed (TSS) Sensor (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6F35)
TuShaft Speed (TSS) Sensor (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - Aisin AW21)
Turn Signal and Hazard Lamps (DIAGNOSIS AND TESTING, Exterior Lighting)
T 4692
U
Uni-Body, Subframe and Mounting System (Section Table of Contents)
Uni-Body, Subframe and Mounting System (SPECIFICATIONS)
Universal Joints (DESCRIPTION AND OPERATION, Driveshaft)
Universal Serial Bus (USB) Cable and Port (REMOVAL AND INSTALLATION, Information and
Universal Transmitter (DESCRIPTION AND OPERATION, Remote Convenience)
Universal Transmitter (DIAGNOSIS AND TESTING, Remote Convenience)
Universal Transmitter Programming (GENERAL PROCEDURES, Remote Convenience)
Upper Arm (REMOVAL AND INSTALLATION, Front Suspension)
Upper Arm (REMOVAL AND INSTALLATION, Rear Suspension)
Upper Intake Manifold (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Upper Intake Manifold (IN-VEHICLE REPAIR, Engine - 3.5L)
Using This Manual (DESCRIPTION AND OPERATION, Service Information)
V
Valve Clearance Check (GENERAL PROCEDURES, Engine - 2.5L)
Valve Clearance Check (GENERAL PROCEDURES, Engine - 2.5L Hybrid)
Valve Clearance Check (GENERAL PROCEDURES, Engine - 3.5L)
Valve Cover (IN-VEHICLE REPAIR, Engine - 2.5L)
Valve Cover (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Valve Cover - LH (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Valve Cover - LH (IN-VEHICLE REPAIR, Engine - 3.5L)
Valve Cover - RH (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Valve Cover - RH (IN-VEHICLE REPAIR, Engine - 3.5L)
Valve Guide Inner Diameter (GENERAL PROCEDURES, Engine System - General Information)
Valve Inspection (GENERAL PROCEDURES, Engine System - General Information)
Valve Seals (IN-VEHICLE REPAIR, Engine - 2.5L)
U 4693
Valve Seals (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Valve Seat Inspection (GENERAL PROCEDURES, Engine System - General Information)
Valve Seat Runout (GENERAL PROCEDURES, Engine System - General Information)
Valve Seat Width (GENERAL PROCEDURES, Engine System - General Information)
Valve Spring Free Length (GENERAL PROCEDURES, Engine System - General Information)
Valve Spring Installed Length (GENERAL PROCEDURES, Engine System - General Information)
Valve Spring Squareness (GENERAL PROCEDURES, Engine System - General Information)
Valve Spring Strength (GENERAL PROCEDURES, Engine System - General Information)
Valve Spring, Retainer and Seal (INSTALLATION, Engine - 3.5L)
Valve Spring, Retainer and Seal (REMOVAL, Engine - 3.5L)
Valve Spring, Retainer, and Seal (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Valve Springs (IN-VEHICLE REPAIR, Engine - 2.5L)
Valve Springs (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Valve Stem Diameter (GENERAL PROCEDURES, Engine System - General Information)
Valve Stem to Valve Guide Clearance (GENERAL PROCEDURES, Engine System - General Information)
Valve Tappet Inspection (GENERAL PROCEDURES, Engine System - General Information)
Valve Tappets (IN-VEHICLE REPAIR, Engine - 2.5L)
Valve Tappets (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Valve Tappets (INSTALLATION, Engine - 3.5L)
Valve Tappets (REMOVAL, Engine - 3.5L)
Valve Train Components - Exploded View (IN-VEHICLE REPAIR, Engine - 2.5L)
Valve Train Components - Exploded View (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Valve Train Components - Exploded View (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Variable Camshaft Timing (VCT) Oil Control Solenoid (REMOVAL AND INSTALLATION, Electronic
Engine Controls - 2.5L)
Engine Controls - 3.0L (4V))
Engine Controls - 3.5L)
V 4694
Engine Controls - Hybrid)
Variable Camshaft Timing (VCT) System Oil Filter (IN-VEHICLE REPAIR, Engine - 2.5L)
Variable Camshaft Tim) System Oil Filter (IN-VEHICLE REPAIR, Engine - 2.5L Hybrid)
Variable Camshaft Timing (VCT) System Oil Filter (IN-VEHICLE REPAIR, Engine - 3.0L (4V))
Vehicle Speed Sensor (VSS) (IN-VEHICLE REPAIR, Manual Transaxle/Transmission)
Video Cable (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Video Camera (REMOVAL AND INSTALLATION, Parking Aid)
Visual Inspection (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6F35)
Visual Inspection (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - Aisin AW21)
W
Warning Chimes (DESCRIPTION AND OPERATION, Instrumentation, Message Center, and Warning
Chimes)
Washer Pump (REMOVAL AND INSTALLATION, Wipers and Washers)
Washer Reservoir (REMOVAL AND INSTALLATION, Wipers and Washers)
Weld-Bonding (GENERAL PROCEDURES, Body Repairs)
Welding Precautions - Steel (DESCRIPTION AND OPERATION, Body Repairs)
Wheel Alignment Angles (DESCRIPTION AND OPERATION, Suspension System - General Information)
Wheel and Tire (DISASSEMBLY AND ASSEMBLY, Wheels and Tires)
Wheel and Tire (REMOVAL AND INSTALLATION, Wheels and Tires)
Wheel Bearing and Wheel Hub (REMOVAL AND INSTALLATION, Front Suspension)
Wheel Bearing and Wheel Hub (REMOVAL AND INSTALLATION, Rear Suspension)
Wheel Knuckle (REMOVAL AND INSTALLATION, Front Suspension)
Wheel Knuckle (REMOVAL AND INSTALLATION, Rear Suspension)
Wheel Speed Sensor - Front (REMOVAL AND INSTALLATION, Anti-Lock Brake System (ABS) and
Stability Control)
Wheel Speed Sensor - Rear, All Wheel Drive (AWD) (REMOVAL AND INSTALLATION, Anti-Lock Brake
System (ABS) and Stability Control)
W 4695
Wheel Speed Sensor - Rear, Front Wheel Drive (FWD) (REMOVAL AND INSTALLATION, Anti-Lock
Brake System (ABS) and Stability Control)
Wheel Spindle (REMOVAL AND INSTALLATION, Rear Suspension)
Wheel Studs (REMOVAL AND INSTALLATION, Front Suspension)
Wheel Studs (REMOVAL AND INSTALLATION, Rear Suspension)
Wheels And Tires (DESCRIPTION AND OPERATION, Wheels and Tires)
Wheels And Tires (DIAGNOSIS AND TESTING, Wheels and Tires)
Wheels and Tires (Section Table of Contents)
Wheels and Tires (SPECIFICATIONS)
Window Control Switch (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Window Glass - Front Door (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Window Glass - Rear (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Window Glass - Rear Door (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Window Glass - Rear Door, Fixed (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Window Grid Wire Repair (GENERAL PROCEDURES, Glass, Frames and Mechanisms)
lass="nospace">Window Motor Initialization (GENERAL PROCEDURES, Glass, Frames and Mechanisms)
Window Regulator and Motor - Front Door (REMOVAL AND INSTALLATION, Glass, Frames and
Mechanisms)
Window Regulator and Motor - Rear Door (REMOVAL AND INSTALLATION, Glass, Frames and
Mechanisms)
Window Regulator Motor (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Windshield Glass (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Wiper and Washer System - Exploded View (REMOVAL AND INSTALLATION, Wipers and Washers)
Wiper Blade and Pivot Arm Adjustment (GENERAL PROCEDURES, Wipers and Washers)
Wiper Motor (REMOVAL AND INSTALLATION, Wipers and Washers)
Wiper Mounting Arm and Pivot Shaft (REMOVAL AND INSTALLATION, Wipers and Washers)
Wiper Pivot Arm (REMOVAL AND INSTALLATION, Wipers and Washers)
Wiper/Washer Module (REMOVAL AND INSTALLATION, Wipers and Washers)
Wipers and Washers (DESCRIPTION AND OPERATION)
W 4696
Wipers and Washers (DIAGNOSIS AND TESTING)
Wipers and Washers (Section Table of Contents)
Wipers and Washers (SPECIFICATIONS)
W 4697
SECTION 211-00A: Steering System - Electronic 2012 Fusion, MKZ, Fusion Hybrid, MKZ
Power Assist Steering (EPAS) Hybrid Workshop Manual
Steering System
Electronic Power Assist Steering (EPAS) System
The Electronic Power Assist Steering (EPAS) system consists of the following components:
• Power Steering Control Module (PSCM) - the PSCM controls the functions of the EPAS system and
communicates with other modules that are on the High Speed Controller Area Network (HS-CAN)
bus. The PSCM is attached to the RH side of the EPAS gear assembly and is not available separately
for service.
• Motor - the EPAS gear uses a 12-volt reversible motor to control the steering effort. The motor is
connected to the steering rack by a toothed belt and a pulley/bearing assembly. The motor is used by
the PSCM to move the rack inside the gear housing. Motor position is used to determine steering
wheel angle/position instead of using a separate sensor. The motor is attached to the RH side of the
EPAS gear assembly and is not available separately for service.
• Steering shaft torque sensor - the steering shaft torque sensor is used by the PSCM to determine how
much force the steering wheel is being turned. The sensor sends out 2 signals, one for left and one for
right. When the steering wheel is turned to the left, the left signal increases while the right signal
decreases, likewise when the steering wheel is turned to the right, the right signal increases while the
left signal decreases. This allows the PSCM EPAS gear assembly and is not available separately for
service.
• Inner tie rod - one inner tie rod is located at each end of the EPAS gear assembly and is available
separately for service. Refer to Section 211-02 .
• Outer tie rod - one outer tie rod is located at each end of the EPAS gear assembly and is available
separately for service. Refer to Section 211-02 .
• EPAS gear bellows boot - one bellows boot is located on each side of the EPAS gear assembly. Each
boot is held in place with 2 boot clamps. The boots and clamps are available for service, refer to
Section 211-02 .
• EPAS gear isolators - there are several rubber isolators (one at each attaching point) on the EPAS gear
assembly. These isolators aid in reducing NVH concerns and not available separately for service.
The EPAS system utilizes a rack-and-pinion type steering gear. Power assist is provided by a motor that is
connected to the steering rack by a belt and a pulley and bearing assembly. The steering gear and
motor/module are serviced as an assembly. A new steering gear includes inner tie rods, however, the inner and
outer tie rods can also be serviced separately. For information on tie-rod end service, refer to Section 211-02 .
P>
Steering System 4698


SECTION 211-00A: Steering System - Electronic 2012 Fusion, MKZ, Fusion Hybrid, MKZ
Power Assist Steering (EPAS) Hybrid Workshop Manual
Steering System
Special Tool(s)
Flex Probe Kit



Electronic Power Assist Steering (EPAS) System
The Electronic Power Assist Steering (EPAS) system provides power steering assist to the driver by replacing
the conventional hydraulic valve system with an electric motor coupled to the steering rack by a toothed belt.
The motor is controlled by the Power Steering Control Module (PSCM) that senses steering effort/use through
the use of a torque sensor which is mounted near the input shaft of the steering gear. Steering assist is
provided in proportion to the steering input effort and vehicle speed.
The EPAS system requires a 12-volt, hot at all times feed for system operation. The PSCM is activated when
power is applied to the hard-wired ignition/run input. After activation, the PSCM monitors the High Speed
Controller Area Network (HS-CAN) bus to determine if the vehicle is operating in a manner capable of
supporting the EPAS system.
Once this is determined, vehicle speed sent by the PCM over the HS-CAN bus, steering shaft speed and
direction sent by the torque sensor and steering wheel angle/position determined by the motor position all
provide the necessary information for the PSCM to determine the amount or level of assist provided by the
EPAS system.
Assist is primarily based off of vehicle speed. As vehicle speed increases, the amount of assist provided by the
system is decreased to improve and enhance road feel at the steering wheel. As vehicle speed decreases, the
amount of assist provided by the system is increased to ease vehicle maneuvering. If the vehicle speed is
missing or out of range, the PSCM defaults to a safe level of assist for all driving conditions. If the vehicle
speed returns to the correct in-range values, the PSCM will adjust the level of assist accordingly. Steering
wheel/shaft torque, speed and direction information will allow the PSCM to determine how much assist is
needed to turn the wheels right and left.
The PSCM is self-monitoring and has the capability of setting and storing DTCs. Depending on the DTC set,
the control module will enter into a "safe mode" of manual steering. In addition, the PSCM may send a
request to the Instrument Panel Cluster (IPC) module over the HS-CAN bus to display a message in the

message center to alert the driver of a potential EPAS concern.
Interactive Diagnostics
For diagnosing and testing please refer to the on-line Workshop Manual. If you do not have an on-line
subscription, go to www.motorcraftservice.com.

SECTION 211-00B: Steering System - Hydraulic Power Assist 2012 Fusion, MKZ, Fusion Hybrid,
Steering (HPAS) MKZ Hybrid Workshop Manual
Material

Capacity
Dye-Lite® ATF/Power Steering - -
Fluid Leak Detection Dye
164-R3701 (Rotunda)
MERCON® V Automatic MERCON® V 1.5L
Transmission Fluid (3.2pt)
XT-5-QM (or XT-5-QMC) (US);
CXT-5-LM12 (Canada)
Item Specification
Power Steering Gear
Turning effort 35 N (7.86 lb)
Power Steering Pump
Flow Minimum capacity 5.3L/min (1.4 gpm)
(while turning steering wheel)
Fluid @ 74°-80°C (165°-175°F)
Pressure 5,171 kPa (750 psi)
Engine @ 675 rpm

Pressure 689 kPa (50 psi)
Fluid @ 74°-80°C (165°-175°F)
Engine @ 2,000 rpm

Relief pressure 9,720-10,170 kPa
(1,409-1,475 psi)
Power Steering Purge Vacuum
Air purge vacuum 68-85 kPa (20-25 in-Hg)


SECTION 211-00B: Steering System - Hydraulic Power 2012 Fusion, MKZ, Fusion Hybrid, MKZ
Assist Steering (HPAS) Hybrid Workshop Manual
Steering System
The power steering system consists of the following components:
• Power steering pump

• Power steering fluid reservoir
• Steering gear
• Power steering fluid cooler
• Power steering lines
• Steering column
• Steering column shaft
The power steering system transfers driver inputs at the steering wheel to the front wheels of the vehicle. The
steering column, hydraulic system and linkages that transfer these driver inputs make up the steering system.
Gearing and hydraulic assist are used to significantly reduce steering efforts.
For information on the power steering fluid reservoir, power steering pump, power steering lines and steering
gear, refer to Section 211-02 .
For information on the steering wheel, steering column and steering column shaft, refer to Section 211-04 .

SECTION 211-00B: Steering System - Hydraulic 2012 Fusion, MKZ, Fusion Hybrid, MKZ
Power Assist Steering (HPAS) Hybrid Workshop Manual
Steering System
Special Tool(s)
100W/12 Volt DC UV Lamp

164-R0751
Dial Thermometer 0-220°F

Evacuation Cap, Power Steering

Vacuum Pump Kit


Material
Item Specification
Dye-Lite® ATF/Power Steering Fluid -
Leak Detection Dye
164-R3701 (Rotunda)
MERCON® V Automatic MERCON®
Transmission Fluid V
CXT-5-LM12 (Canada)
Power Steering
The power steering system uses a vane-type pump to move the fluid from the reservoir to the steering gear
and through the rest of the steering hydraulic system. The power steering pump is mounted to the engin driven
by the engine accessory drive belt. Power steering fluid flows into the pump from the reservoir. The power
steering fluid is then trapped between the pump vanes and moved to the high-pressure side of the pump
creating a flow of fluid. The restriction of this flow by the steering gear creates the pressure that provides the
steering assist. A combined pressure relief/flow valve is built into the pump to control the maximum pressure
and flow provided to the steering system. This action prevents damage to the system and provides the correct
level of assist during all engine speeds. While under pressure, the power steering fluid flows through the
high-pressure power steering line to the steering gear. The fluid exits the gear and flows through the return
line, cooler and finally to the reservoir. The reservoir slows the fluid, allows air to escape and filters the fluid

before returning it to the pump.
2. Visually inspect for obvious signs of mechanical damage.
Mechanical
• Fluid level
• Tire pressure
• Tires
• Drive belt
• Drive belt tensioner
• Steering column alignment
• Tie-rod ends
• Suspension components
• Steering column shaft U-joints
• Intermediate shaft bolts
• Power steering reservoir baffle
• Power steering reservoir screen
• Power steering pressure lines, fittings or
O-rings
• Power steering return hoses and clamps
• Steering gear
• Power steering pressure switch
3. Inspect the power steering fluid for the following conditions:

• Aeration or foam: Purge the power steering system. Refer to Power Steering System Purging
in this section.
• Overheating or contamination: Flush the power steering system. Refer to Power Steering
System Flushing in this section.
4. NOTE: It may be necessary to add power steering fluid to achieve the correct level.
Check the fluid level and clean the power steering components.
With the ignition OFF:
• check the power steering fluid level and add fluid as necessary.
• wipe off any visible signs of fluid or residue build up.
• NOTICE: Do not hold the steering wheel at the stops for an extended amount of time.
Damage to the power steering pump may occur.
Start the engine and turn the steering wheel from stop-to-stop several times.
Power Steering 4706

5. Visually inspect the power steering hydraulic line/hose connections for leaks.
• If a leak is detected at a threaded fitting or clamp plate joint, tighten to specification. If the
leak is still evident, visually inspect the O-rings or Teflon® seals. Install new O-rings or
Teflon® seals as necessary. Refer to
• If a leak is detected at a constant tension spring clamp, verify that the hose is not damaged
and fully installed on the hose fitting. Make sure that the constant tension spring clamp is
positioned 2 mm (0.078 in) from the end of the hose. If the leak remains, install a new
constant tension spring clamp.
• If a leak is detected at a screw clamp joint, verify that the hose is fully installed on the hose
fitting and the clamp is positioned 2 mm (0.078 in) from the end of the hose before tightening
the screw clamp. If the leak remains, install a new screw clamp. Refer to Section 211-02 .
• If a leak is detected at the power steering pressure switch, install a new switch. Refer to the
appropriate section in Group 303 for the procedure.
6. Visually inspect the power steering components for leaks.

• If a leak is detected in the power steering pressure line or return hose, install a new hose.
• If a leak is detected in the power steering pump, install a new power steering pump. Refer to
Section 211-02 .
• NOTE: On vehicles with rack-and-pinion steering gear, it may be necessary to remove the
bellows boot clamp from the steering gear bellows boot to inspect for internal steering gear
leaks.
If a leak is detected in the steering gear, repair or install a new steering gear. Refer to Section
211-02 .
• If a leak is detected in the power steering reservoir, install a new reservoir. Refer to Section
211-02 .
7. For information on power steering leak detection, refer to Component Tests in this section.
proceeding.
9. If the cause is not visually evident, verify the symptom and GO to Symptom Chart - Steering System
or GO to Symptom Chart - NVH .
Steering System Symptom Definitions
Drift/Pull
Pull is described as a tugging sensation felt by the hands on the steering wheel that must be overcome to keep
the vehicle going straight.
Drift describes what a vehicle with this condition does with the hands off the steering wheel.
• A vehicle-related drift/pull on a flat road can cause a consistent deviation from the straight-ahead path
and require constant steering input in the opposite direction to counteract the effect.
• Drift/pull can be induced by conditions external to the vehicle, such as wind or road camber.
Excessive Steering Wheel Play
Excessive steering wheel play is a condition in which there is too much steering wheel movement before the
wheels move. A small amount of steering wheel free play is considered normal.
Drift/Pull 4707
Lack of Assist or Inconsistent Assist
Lack of assist or inconsistent assist is experienced when the steering wheel effort is higher than normal. Hard
steering can remain constant through the full turn or occur near the end of a turn. It is important to know the
difference between hard steering/lack of assist and poor returnability/sticky steering.
Hard steering or lack of assist can result from either hydraulic or mechanical conditions. It is extremely
important to know if this concern occurs during driving or during high-effort parking maneuvers.
Poor Returnability/Sticky Steering
Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a
turn or steering correction is completed.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to
maintain a straight path down a level road.
Symptom Chart - Steering System
Symptom Chart - Steering System
Symptom Chart - NVH
Lack of Assist or Inconsistent Assist 4708

SECTION 211-00B: Steering System - Hydraulic Power 2012 Fusion, MKZ, Fusion Hybrid,
Assist Steering (HPAS) MKZ Hybrid Workshop Manual
Power Steering System Flushing
Material
Item Specification
CXT-5-LM12 (Canada)
NOTICE: Do not mix fluid types. Any mixture or any unapproved fluid may lead to seal deterioration
and leaks. A leak may ultimately cause loss of fluid, which may result in a loss of power steering assist.
1. Remove the power steering fluid reservoir cap.
2. Using a sule suction device, remove the power steering fluid from the reservoir.
3. Release the clamp and disconnect the return hose from the reservoir.
• Remove the clamp from the hose and allow the remaining fluid to drain out of the reservoir.
4. Plug the power steering fluid reservoir inlet port.
5. Attach an extension hose to the return hose.
6. NOTE: Do not reuse the power steering fluid that has been flushed from the power steering system.
Place the open end of the extension hose into a suitable container.
7. If equipped with Hydro-Boost®, apply the brake pedal 4 times.
8. NOTE: Do not overfill the reservoir.
Fill the reservoir as needed with the specified fluid.
9. NOTICE: Do not allow the power steering pump to run completely dry of power steering fluid.
Start the engine while simultaneously turning the steering wheel to lock and then immediately turn the
ignition switch to the OFF position.
10. NOTE: Avoid turning the steering wheel without the engine running as this may cause air to be
pulled into the steering gear.
NOTE: Do not overfill the reservoir.
11. Repeat Steps 8 and 9, turning the steering wheel in the opposite direction each time, until the fluid
exiting the power steering fluid return hose is clean and clear of foreign material.
Wander 4709
12. Remove the extension hose from the return hose.
13. Remove the plug from the fluid reservoir inlet port.
14. Install the clamp and connect the power steering return hose to the resevoir.
15. NOTE: It is necessary to correctly fill the power steering system to remove any trapped air and
completely fill the power steering system components.
If, after correctly filling the power steering system, there is power steering noise accompanied by
evidence of aerated fluid and there are no fluid leaks, it may be necessary to purge the power steering
system. For additional information, refer to Power Steering System Purging in this section.
Fill the power steering system. For additional information, refer to Power Steering System Filling in
this section.
Power Steering System Flushing 4710

Power Steering System Purging
Special Tool(s)

211-265
Vacuum Pump Kit

MaterialItemSpecificationMERCON® V Automatic Transmission Fluid

XT-5-QM (or XT-5-QMC) (US); CXT-5-LM12 (Canada)MERCON® V
NOTICE: If the air is not purged from the power steering system correctly, premature power steering
pump failure may result. The condition may occur on pre-delivery vehicles with evidence of aerated
fluid or on vehicles that have had steering component repairs.
1. NOTE: A whine heard from the power steering pump can be caused by air in the system. The power
steering purge procedure must be carried out prior to any component repair for which power steering
noise complaints are accompanied by evidence of aerated fluid.
Remove the power steering reservoir cap. Check the fluid.
2. Raise the front wheels off the floor. Refer to the appropriate section in Group 100 for the procedure.
3. Tightly insert the Power Steering Evacuation Cap into the reservoir and connect the Vacuum Pump
Kit.
5. Using the Vacuum Pump Kit, apply vacuum and intain the maximum vacuum of 68-85 kPa (20-25
in-Hg).
• If the Vacuum Pump Kit does not maintain vacuum, check the power steering system for
leaks before proceeding. For additional information, refer to Power Steering Fluid Leak Test
in this section.
6. If equipped with Hydro-Boost®, apply the brake pedal 4 times.
Power Steering System Purging 4711

7. NOTICE: Do not hold the steering wheel against the stops for an extended amount of time.
Cycle the steering wheel fully from stop-to-stop 10 times.
8. Stop the engine.
9. Release the vacuum and remove the Vacuum Pump Kit and the Power Steering Evacuation Cap.
12. Install the Power Steering Evacuation Cap and the Vacuum Pump Kit. Apply and maintain the
maximum vacuum of 68-85 kPa (20-25 in-Hg).
Cycle the steering wheel fully from stop-to-stop 10 times.
14. Stop the engine, release the vacuum and remove the Vacuum Pump Kit and the Power Steering
Evacuation Cap.
Fill the reservoir as needed with the specifie fluid and install the reservoir cap.
16. Visually inspect the power steering system for leaks.


Power Steering System Filling
Special Tool(s)

211-265
Fill Adapter Manifold, Power Steering

211-327
Vacuum Pump Kit

Material
Item Specification
CXT-5-LM12 (Canada)
Item Description
1 Power steering fluid reservoir
2 Control valve (vacuum side)
3 Control valve (fluid container side)
4 Fluid container
1. NOTICE: If the air is not purged from the power steering system correctly, prature power
steering pump failure may result. The condition can occur on pre-delivery vehicles with
Power Steering System Filling 4714

evidence of aerated fluid or on vehicles that have had steering component repairs.
Remove the power steering fluid reservoir cap.
2. Install the Power Steering Evacuation Cap, Power Steering Fill Adapter Manifold and Vacuum Pump
Kit as shown in the illustration.
3. NOTE: The Power Steering Fill Adapter Manifold control valves are in the OPEN position when the
points of the handles face the center of the Power Steering Fill Adapter Manifold.
Close the Power Steering Fill Adapter Manifold control valve (fluid side).
4. Open the Power Steering Fill Adapter Manifold control valve (vacuum side).
5. Using the Vacuum Pump Kit, apply 68-85 kPa (20-25 in-Hg) of vacuum to the power steering system.
6. Observe the Vacuum Pump Kit gauge for 30 seconds.
7. If the Vacuum Pump Kit gauge reading drops more than 3 kPa (0.88 in-Hg), correct any leaks in the
power steering system or the Power Steering Evacuation Cap, Power Steering Fill Adapter Manifold
and Vacuum Pump Kit before proceeding.
8. NOTE: The Vacuum Pump Kit gauge reading will drop slightly during this step.
Slowly open the Power Steering Fill Adapter Manifold control valve (fluid side) until power steering
fluid completely fills the hose and then close the control valve.
9. Using the Vacuum Pump Kit, apply 68-85 kPa (20-25 in-Hg) of vacuum to the power steering system.
10. Close the Power Steering Fill Adapter Manifold control valve (vacuum side).
11. Slowly open the Power Steering Fill Adapter Manifold control valve (fluid side).
12. Once power steering fluid enters the fluid reservoir and reaches the minimum fluid level indicator line
on the reservoir, close the Power Steering Fill Adapter Manifold control valve (fluid side).
13. Remove the Power Steering Evacuation Cap, Power Steering Fill Adapter Manifold and Vacuum
Pump Kit.
14. Install the reservoir cap.
NOTE: There will be a slight drop in the power steering fluid level in the reservoir when the engine
is started.
Start the engine and turn the steering wheel from stop-to-stop.
16. Turn the ignition switch to the OFF position.
Remove the reservoir cap and fill the reservoir with the specified fluid.

18. Install the reservoir cap.


SECTION 211-02: Power Steering
Manual
Material
Item SpecificationFill
Capacity
MERCON® V Automatic MERCON® V 1.4L (2.5 ) a
Transmission Fluid
CXT-5-LM12 (Canada)
CXG-1-C (Canada)
a Capacities listed are average system capacities and may vary (3.5L only).

Catalytic converter-to-exhaust flexible pipe nuts (3.5L) 40 30 -
Damper fork-to-front lower arm bolt 103 76 -
Electronic Power Assist Steering (EPAS) ground wire bolt 10 - 89
Exhaust bracket with U-clamp bolts and nuts (2.5L) 30 22 -
Inner tie rod 103 76 -
Lower stabilizer bar link nuts 42 31 -
Outer tie-rod end nuts 48 35 -
Power steering fluid reservoir bracket bolts (3.5L) 7 - 62
Power steering pump bolts (3.5L) 24 18 -
Pressure line bracket-to-RH valve cover stud nut (3.5L) 9 - 80
Pressure line bracket-to-steering gear bolt (3.5L) 15 - 133
Pressure line-to-power steering pump banjo bolt (3.5L) 48 35 -
Pressure line-to-steering gear banjo bolt (3.5L) 55 41 -
Roll restrictor bolt 90 66 -
Steering column shaft-to-steering gear bolt (2.5L and 3.0L) 20 - 177
Steering column shaft-to-steering gear bolt (3.5L) 25 18 -
Steering gear bolts 107 79 -
Subframe bolts 103 76 -
Tie-rod jam nuts 80 59 -
Underbody splash shield bolts-to-subframe 7 - 62



Manual
Power Steering
Hydraulic Power Assist Steering (HPAS)
The hydraulic power steering system consists of the following components:

• Power steering fluid reservoir
• Power steering pressure and return lines/hoses
• Power steering fluid cooler
• Steering gear
• Inner tie rod
• Outer tie rod
The power steering system uses a vane-type pump to move the fluid from the reservoir to the steering gear
and through the rest of the steering hydraulic system. The power steering pump is mounted to the engine and
driven by a non-adjustable (stretchy) belt. Power steering fluid flows into the pump from the reservoir. The
power steering fluid is then trapped between the pump vanes and moved to the high-pressure side of the pump
creating a flow of fluid. The restriction of this flow by the steering gear creates the pressure that provides the
steering assist. A combined pressure relief/flow valve is built into the pump to control the maximum pressure
and flow provided to the steering system. This action prevents damage to the system and provides the correct
level of assist during all engine speeds. While under pressure, the power steering fluid flows through the
high-pressure power steering line to the steering gear. The fluid exits the gear and flows through the return
line, cooler and finally to the reservoir. The reservoir slows the fluid, allows air to escape and filters the fluid
before returning it to the pump.
Electronic Power Assist Steering (EPAS)
The Electronic Power Assist Steering (EPAS) consists of the following components:
• Steering gear
• Outer tie rod
• Inner tie rod
The EPAS system utilizes a rack-and-pinion type steering gear. Power assist is provided by a motor that is
connected to the steering rack by a belt and a pulley and bearing assembly. The steering gear and
motor/module are serviced as an assembly. A new steering gear includes inner tie rods, however, the inner and
outer tie rods can also be serviced separately.
Power Steering 4719

Power Steering 4720


Manual
Power Steering
Refer to Section 211-00A or Section 211-00B .
Power Steering 4721


Manual
REMOVAL AND
INSTALLATION
Power Steering Fluid Reservoir - 3.5L
Material
Item Specification
CXT-5-LM12 (Canada)

1 3A697 Power steering fluid reservoir
2 3A713A Power steering return hose and clamp
3 3691 Power steering pump supply hose
4 - Power steering pump supply hose clamp (part of 3691)
5 3490 Power steering fluid reservoir bracket
6 W712963 Power steering fluid reservoir bracket bolt (3 required)
NOTICE: When repairing the power steering system, care should be taken to prevent the entry of
foreign material or failure of the power steering components may result.
1. Using a suitable suction device, remove the power steering fluid from the fluid reservoir.
2. Release the clamp and disconnect the power steering return hose from the power steering fluid
reservoir.
3. Remove the 3 power steering fluid reservoir bracket bolts.
4. Release the power steering pump supply hose clamp and disconnect the supply hose from the
reservoir.
Power Steering Fluid Reservoir - 3.5L 4722

5. NOTE: If a new power steering fluid reservoir is being installed, a new reservoir mounting bracket
must also be installed.
Remove the power steering fluid reservoir and bracket as an assembly.
6. To install, reverse removal procedure.
7. Fill the power steering system. For additional information, refer to Section 211-00B .
Power Steering Fluid Reservoir - 3.5L 4723


Manual
REMOVAL AND
INSTALLATION
Power Steering Pump - 3.5L
Material
Item Specification
CXT-5-LM12 (Canada)
Part
1 - Pressure line-to-power steering pump banjo bolt (part of
3A705 service kit)
2 - Power steering pressure line (part of 3A719 service kit)
3 - Power steering pressure line seals (part of 3A705
service kit)
4 3691 Power steering pump supply hose
5 W701526 Power steering pump bolts (2 required)
6 W701234 Power steering pump bolt
7 - Power Steering Pressure (PSP) switch electrical
connector
8 3N824 PSP switch
9 3A696 Power steering pump
Power Steering Pump - 3.5L 4724

NWhen repairing the power steering system, care should be taken to prevent the entry of foreign material
or failure of the power steering components may result.
1. Remove the power steering fluid reservoir. For additional information, refer to Power Steering Fluid
Reservoir - 3.5L in this section.
2. Remove the power steering pump belt. For additional information, refer to Section 303-05C .
3. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
4. If equipped, detach the engine block heater electrical harness from the power steering pressure line.
5. Remove the pressure line-to-power steering pump banjo bolt and disconnect the line from the power
steering pump.
• Discard the bolt and 2 seals.
• To install, tighten the new bolt to 48 Nm (35 lb-ft).
6. Remove the 3 bolts and the power steering pump.

7. NOTICE: A new banjo bolt and new seals must be installed any time the power steering
pressure line is disconnected from the power steering pump or a fluid leak may occur.
To install, reverse the removal ocedure.
Power Steering Pump - 3.5L 4725


Manual
REMOVAL AND
INSTALLATION
Power Steering Pump to Steering Gear Pressure Line
Material
Item Specification
XT-5-QM (orXT-5-QMC) (US);
CXT-5-LM12 (Canada)
Part
1 W703836 Pressure line bracket-to-RH valve cover stud nut
3 - Pressure line-to-power steering pump banjo bolt (part of
3A719 service kit)
4 - Power steering pressure line seals (part of 3A719 service
kit)
5 - Pressure line-to-steering gear banjo bolt (part of 3A719
service kit)
6 W712115 Pressure line bracket-to-steering gear bolt
7 - Power steering pressure line seals (part of 3A719 service
kit)
Power Steering Pump to Steering Gear Pressure Line 4726

100-02 .
3. NOTE: Battery mounting bracket removed for clarity.
Disconnect the electrical connectors from the PCM.
• Detach harness retainer from the PCM bracket, and position the harness aside.
4. Remove the lower cowl panel grille. For additional information, refer to Section 501-02 .
5. Remove the pressure line bracket-to-RH valve cover stud nut.

• Detach the electrical harness retainer from the pressure line bracket.
6. If equipped, detach the engine block heater harness from the power steering pressure line.
7. Remove the pressure line bracket-to-steering gear bolt.

8. Remove the pressure line-to-power steering pump banjo bolt.

• Discard the bolt and the 2 seals.
9. Remove the pressure line-to-steering gear banjo bolt and remove the power steering pressure line.
• Discard the bolt and the 2 seals.
10. NOTICE: New banjo bolts and new seals must be installed any time the power steering pressure
line is disconnected from the power steering pump and/or the power steering gear or a fluid
leak may occur.
To install, reverse removal procedure.



Manual
REMOVAL AND
INSTALLATION
Power Steering Fluid Cooler - 3.5L
NOTE: The power steering fluid cooler is integral to the A/C condenser core.
For additional information, refer to Section 412-01 .
Power Steering Fluid Cooler - 3.5L 4729


Manual
REMOVAL AND
INSTALLATION
Steering Gear - 3.5L Front Wheel Drive (FWD)
Special Tool(s)
Ball Joint Separator

204-592
Material
Item Specification
CXT-5-LM12 (Canada)
Part
1 - Pressure line-to-steering gear
banjo bolt (part of 3A705
service kit)
Steering Gear - 3.5L Front Wheel Drive (FWD) 4730

2 - Power steering pressure line

seals (part of 3A705 service kit)
3 - Power steering pressure line
(part of 3A719 service kit)
4 3A713 Steering gear-to-fluid cooler
return hose
5 712155 Pressure line bracket-to-steering 6 3C497 Steering gear
gear bolt bolts (3
required)
7 99221 Cotter pin (2 required)
8 6E5C Outer tie-rod end nut (2
required)
9 3504 Steering gear
10 3R827 Steering column
shaft-to-steering gear bolt
11 3611B Steering gear/dash seal
12 W704904 Lower steering column shaft
joint cover nut (2 required)
13 3611A Lower steering column shaft
joint cover
14 391727 Steering gear heat shield
15 3530B Steering gear heat shield bolt (2
required)
16 3C496 Subframe bolt (4 required)
17 W520416 Subframe nut (2 required)
Removal
1. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
2. Remove the wheels and tires. For additional information, refer to Section 204-04 .
3. Remove the 2 lower steering column shaft joint cover nuts and the cover.
4. NOTICE: Make sure to correctly index-mark the steering gear-to-steering column shaft position
or unequal right-to-left turns may occur, causing tire contact with the body and/or clockspring
damage.
Index-mark the steering column shaft-to-steering gear position for reference during installation.

5. NOTICE: Do not allow the steering column to rotate while the steering column shaft is
disconnected from the steering gear or damage to the clockspring may occur. If there is
evidence that the steering column has rotated, the clockspring must be removed and recentered.
For additional information, refer to Section 501-20B .
Remove the bolt and disconnect the steering column shaft from the steering gear.
• Discard the bolt.
Pulling upward, remove the steering gear/dash seal.
8. NOTE: RH side shown, LH side similar.
Remove the 4 screws from each side and position the RH and LH fender splash shield aside.
9. Remove the 6 pin-type retainers (4 shown) from the LH and RH splash shield.

10. Remove the 2 outer tie-rod end cotter pins and nuts.
• Discard the cotter pins.
11. NOTICE: Do not use a hammer to separate the outer tie-rod end from the wheel knuckle or
damage to the wheel knuckle may result.
Using the Ball Joint Separator, separate the outer tie-rod ends from the knuckle.
Remove and discard the 2 catalytic converter-to-exhaust flexible pipe nuts and separate the exhaust
flexible pipe.
13. Remove the 2 bolts and the steering gear heat shield.
15. Remove the pressure line-to-steering gear banjo bolt.

16. Support the rear of the subframe with a suitable jack and remove the 4 rear subframe bolts and 2 rear
subframe nuts.
17. Lower the rear of the front subframe 76.2 mm (3 in) with the support of the jack.
18. Release the clamp and disconnect the steering gear-to-fluid cooler return hose.
19. Remove the 3 steering gear bolts.
20. Remove the steering gear from the LH side of the vehicle.

Installation
1. From the LH side of the vehicle, install the steering gear.
2. Install the 3 steering gear bolts.

3. Release the clamp and connect the steering gear-to-fluid cooler return hose.
4. Using a suitable jack, raise the rear of the front subframe.
5. Install the subframe support bracket, 4 rear subframe bolts and 2 rear subframe nuts.
• To install, tighten the bolts and nuts in 2 stages.
♦ Stage 1: Tighten the nuts to 150 Nm (111 lb-ft).
♦ Stage 2: Tighten the bolts to 103 Nm (76 lb-ft).
line is disconnected from the power steering pump and/or the steering gear or a fluid leak may
occur.
Install the new pressure line-to-steering gear banjo bolt.
• Install 2 new seals.

7. Install the pressure line bracket-to-steering gear bolt.

8. Install the steering gear heat shield and the 2 bolts.

Position the exhaust flexible pipe and install 2 new catalytic converter-to-exhaust flexible pipe nuts.
10. Install the 2 outer tie-rod end nuts.

• Install 2 new cotter pins.
11. Install the LH and RH splash shield and the 6 pin-type retainers.
12. Install the RH and LH fender splash shield and the 4 screws from each side.
13. If equipped, install the underbody splash shield and the 7 screws.
14. NOTICE: The steering gear/dash seal must be fully seated in the steering gear valve tower
groove before the retaining clips are fully engaged into the body. If the steering gear/dash seal is
not seated to the steering gear valve tower groove and the clips are not fully engaged to the
body, water and foreign material may enter the passenger compartment and damage the vehicle
interior.

Applying hand force to the center of the seal, install the steering gear/dash seal onto the steering gear
valve tower until the seal is fully seated in the valve tower groove.
15. Install the steering gear/dash seal until the retaining clips are fully engaged into the body.
NOTICE: Make sure to correctly align the index marks when installing the steering
gear-to-steering column shaft or unequal right-to-left turns may occur, causing tire contact with
the body and/or clockspring damage.
With the index marks properly aligned, connect the steering column shaft to the steering gear and
install the new bolt.
17. Install the lower steering column shaft joint cover and the 2 nuts.
19. Check and, if necessary, adjust the front toe. For additional information, refer to Section 204-00 .



Manual
REMOVAL AND
INSTALLATION
Steering Gear - 3.5L All Wheel Drive (AWD)
Special Tool(s)

204-592
Material
Item Specification
CXT-5-LM12 (Canada)
Part
1 - Pressure line-to-steering gear banjo bolt (part of 3A705
service kit)
Steering Gear - 3.5L All Wheel Drive (AWD) 4737

2 - Power steering pressure line seals (part of 3A705

service kit)
4 3A713 Steering gear-to-fluid cooler return hose
5 W712155 Pressure line bracket-to-steering gear bolt
6 3C497 Steering gear bolts (3 required)
7 99221 Cotter pin (2 required)
8 6E5C Outer tie-rod end nut (2 required)
10 3R827 Steering column shaft-to-steering gear bolt
12 W704904 Lower steering column shaft joint cover nut (2 required)
13 3611A Lower steering column shaft joint cover
14 391727 Steering gear heat shield
15 3530B Steering gear heat shield bolt (2 required)
16 3C496 Subframe bolt (4 required)
17 W520416 Subframe nut (2 required)
Removal
4. NOTICE: Make sure to correctly index-mark the steering gear-to-steering column shaft position
or unequal right-to-left turns may occur, causing tire contact with the body and/or clockspring
damage.
Index-mark the steering column shaft-to-steering gear position for reference during installation.

8. NOTE: Battery mounting bracket removed for clarity.
Disconnect the electrical connectors from the PCM.
• Detach the wiring harness retainer from the PCM bracket and position the harness aside.
9. Remove the pressure line-to-steering gear banjo bolt.

Remove the 4 screws from each side and position the RH and LH fender splash shield aside.

Remove and discard the 2 catalytic converter-to-exhaust flexible pipe nuts and separate the exhaust
flexible pipe.
17. Remove the 2 bolts and the steering gear heat shield.
18. Support the rear of the subframe with a suitable jack and remove the 4 rear subframe bolts and 2 rear
subframe nuts.
19. Lower the rear of the front subframe 76.2 mm (3 in) with the support of the jack.

21. Release the clamp and disconnect the steering gear-to-fluid cooler return hose.
23. Remove the steering gear from the LH side of the vehicle.
Installation
1. From the LH side of the vehicle, install the steering gear.

3. Release the clamp and connect the steering gear-to-fluid cooler return hose.
4. Using a suitable jack, raise the rear of the front subframe.
6. Install the steering gear heat shield and the 2 bolts.

Position the exhaust flexible pipe and install 2 new catalytic converter-to-exhaust flexible pipe nuts.
8. Install the 2 outer tie-rod end nuts.

10. Install the RH and LH fender splash shield and the 4 screws from each side.
11. If equipped, install the underbody splash shield and bolts.

12. Install the pressure line bracket-to-steering gear bolt.

line is disconnected from the power steering pump and/or the steering gear or a fluid leak may
occur.
Install the new pressure line-to-steering gear banjo bolt.
• Install 2 new seals.


14. Connect the electrical connectors to the PCM.
• Attach the wiring harness retainer to the PCM bracket.
interior.
NOTICE: Make sure to correctly align the index marks when installing the steering
gear-to-steering column shaft or unequal right-to-left turns may occur, causing tire contact with
the body and/or clockspring damage.
With the index marks properly aligned, connect the steering column shaft to the steering gear and
install the new bolt.

21. Check and, if necessary, adjust the front toe. For additional information, refer to Section 204-00 .


Manual
REMOVAL AND
INSTALLATION
Steering Gear - 2.5L Hybrid and 3.0L All Wheel Drive (AWD)
Special Tool(s)

204-592
Powertrain Lift

1 W520416 Front subframe nuts (4 required)
2 3C496 Front subframe support bracket bolts (4
required)
3 5884 Subframe support bracket
5 W506410 Electronic P Assist Steering (EPAS) ground
wire bolt
6 5C145 Front subframe
7 - EPAS jumper harness connector (2 required)
8 6E5C Tie-rod end nut (2 required)
Steering Gear - 2.5L Hybrid and 3.0L All Wheel Drive (AWD) 4744

9 W500550 Damper fork-to-front lower arm bolt (2 required)
12 W704904 Lower steering column shaft joint cover nut (2
required)
14 3C494 Lower stabilizer bar link nut (2 required)
15 3053/3052 Stabilizer bar link (2 required)
16 - EPAS electrical connector (part of 3F720) (2 required)
17 3 Steering gear bolt (3 required)
Removal
1. If installing a new steering gear, connect the scan tool and upload the module configuration
information from the Power Steering Control Module (PSCM). For additional information, refer to
Section 418-01 .
Remove the 4 screws from each side and position the RH and LH fender splash shields aside.
Using the Ball Joint Separator, separate the outer tie-rod ends from the wheel knuckles.
13. Remove the engine roll restrictor bolt.
14. Disconnect the 2 Electronic Power Assist Steering (EPAS) jumper harness electrical connectors and
detach the 3 wiring harness retainers.
15. Remove the bolt and position the ground wire aside.
16. Remove the 2 (one on each side) lower stabilizer bar link nuts and separate the links from the
stabilizer bar.
17. Remove the 2 damper fork-to-front lower arm bolts and flagnuts.
18. Position the Powertrain Lift under the subframe.
19. Remove the 2 rear mounting nuts and washers from the front subframe.
20. Remove the 4 bolts and the subframe support bracket.
21. Remove the 2 front mounting nuts and washers from the front subframe.
22. Lower the subframe to gain access to the steering gear.
23. Disconnect the 2 EPAS electrical connectors and the wiring retainer.
24. Remove the 3 bolts and the steering gear.
Installation
1. Position the steering gear and install the 3 bolts.

2. Connect the 2 EPAS electrical connectors and the wiring retainer.
3. Raise the subframe.
4. Install the 2 front subframe nuts and washers.

6. Install the 2 damper fork-to-front lower arm bolts and flagnuts.

7. Connect the stabilizer bar links and install the 2 nuts.

8. Position the ground wire and install the bolt.

9. Connect the 2 EPAS jumper harness electrical connectors and attach the 3 wiring harness retainers.
10. Install the engine roll restrictor bolt.

12. Position the 2 outer tie-rod ends and install the nuts.
14. Install the RH and LH fender splash shields and the 4 screws from each side.
15. If equipped, install the underbody cover and the 7 screws.
body, water and foreign material may enter the passenger compartment, and damage the
vehicle interior.
With the locator on the input shaft correctly aligned, connect the steering column shaft to the steering
gear and install the new bolt.
20. When installing a new steering gear, it must be configured (using vehicle as-built data or module
configuration information retrieved earlier in this procedure). For additional information on
configuration, refer to Programmable Module Installation (PMI) in Section 418-01 .
21. Check, and If necessary, adjust the front toe. Refer to Section 204-00 .

Manual
REMOVAL AND
INSTALLATION
Steering Gear - 2.5L Non-Hybrid and 3.0L Front Wheel Drive (FWD)
Special Tool(s)

204-592

1 W520416 Front subframe nuts (4 required)
2 3C496 Front subframe support bracket bolts (4 required)
3 5884 Subframe support bracket
5 5C145 Front subframe
6 6E5C Tie-rod end nut (2 required)
Steering Gear - 2.5L Non-Hybrid and 3.0L Front Wheel Drive (FWD) 4750
Part
7 W704904 Lower steering column shaft joint cover nut (2 required)
11 - Electronic Power Assist Steering (EPAS) electrical
connector (part of 3F720) (2 required)
12 3C497 Steering gear bolt (3 required)
Removal
All vehicles
1. If installing a new steering gear, connect the scan tool and upload the module configuration
information from the Power Steering Control Module (PSCM). For additional information, refer to
Section 418-01 .
Remove the 4 screws from each side and position the RH and LH fender splash shields aside.
9. Remove the 6 pin-type retainers (4 shown) from the LH and RH splash shields.
Vehicles equipped with 2.5L engines
12. Remove the 2 bolts, 2 nuts and the exhaust bracket with U-clamp.
All vehicles
14. Disconnect the 2 EPAS electrical connectors and the wiring retainer.
15. Remove the engine roll restrictor bolt.
16. Support the rear of the subframe with a suitable jack, remove the 4 rear subframe bolts and 2 rear
subframe nuts and the subframe support bracket.
• Loosen the 2 front subframe nuts.
17. Using the jack, lower the rear of the front subframe 76.2 mm (3 in).
19. Remove the steering gear from the vehicle.
Installation
All vehicles
1. Install the steering gear.

3. Using the jack, raise the rear of the front subframe.
4. Tighten the 2 front subframe nuts.

5. Install the subframe support bracket, the 4 rear subframe bolts and the 2 rear subframe nuts.

6. Install the engine roll restrictor bolt.

7. Connect the 2 EPAS electrical connectors and the wiring retainer.
9. Install the 2 bolts, 2 nuts and the exhaust bracket with U-clamp.
All vehicles
10. Position the outer tie-rod ends and install the 2 nuts.
12. Install the RH and LH fender splash shields and the 4 screws from each side.
13. If equipped, install the underbody splash shield and bolts.

interior.
With the locator on the input shaft properly aligned, connect the steering column shaft to the steering
gear and install the new bolt.
18. When installing a new steering gear, it must be configured (using vehicle as-built data or module
configuration information retrieved earlier in this procedure). For additional information on
configuration, refer to Programmable Module Installation (PMI) in Section 418-01 .

Manual
REMOVAL AND
INSTALLATION
Tie Rod - Inner
Material
Item Specification
(Canada)
NOTE: Hydraulic Power Assist Steering (HPAS) shown, Electronic Power Assist Steering (EPAS) similar.
Part
1 3280 Hydraulic Power Assist Steering (HPAS) inner tie-rod
end (also part of 3332B service kit)
1 - Electronic Power Assist Steering (EPAS) inner tie-rod
end (part of 3280 service kit)
2 3K745 HPAS inner bellows boot clamp (also part of 3332B
service kit)
2 - EPAS inner bellows boot clamp (part of 3280 service kit)
3 3K661 HPAn> bellows boot (also part of 3332B service kit)
3 - EPAS bellows boot (part of 3280 service kit)
4 3C650 HPAS outer bellows boot clamp (also part of 3332B
service kit)
4 - EPAS outer bellows boot clamp (part of 3280 service kit)
5 W713882 Tie-rod jam nut (all)
6 3A130 Outer tie-rod end (all)
7 W302124 Outer tie-rod end nut (all)
Tie Rod - Inner 4756

8 W302420 Cotter pin (all)

9 - Retaining washer (Hydraulic Power Assist Steering
(HPAS) only) (part of 3280 and 3332B service kit)
NOTICE: When servicing inner tie rods, a new bellows boot and clamps must be installed or a leak may
occur causing steering gear damage.
1. Remove the steering gear. For additional information, refer to Steering Gear - 3.5L Front Wheel Drive
(FWD) , Steering Gear - 3.5L All Wheel Drive (AWD) , Steering Gear - 2.5L Non-Hybrid and 3.0L
Front Wheel Drive (FWD) or Steering Gear - 2.5L Hybrid and 3.0L All Wheel Drive (AWD) in this
section.
2. NOTICE: Position the steering gear in a soft-jaw vise or damage to the steering gear may occur.
Loosen the tie-rod jam nut and remove the outer tie-rod end.
3. NOTE: It will be necessary to partially remove the LH bellows boot to hold the rack piston when
servicing the RH inner tie rod.
If servicing the RH inner tie rod, remove the LH inner bellows boot clamp and slide the bellows boot
away from the steering gear housing.
• Discard the clamp.
4. Remove and discard the 2 bellows boot clamps and the bellows boot for the inner tie rod being
serviced.
5. On Hydraulic Power Assist Steering (HPAS) steering gears, bend back the crimped edges of the
retaining washer.
6. NOTICE: The steering gear rack piston must be held while loosening or tightening the inner tie rod or
damage to the steering gear may occur.Using a suitable wrench, hold the piston shaft.
7. Using a suitable wrench, remove the inner tie-rod end.

8. NOTICE: When installing the bellows boot(s), grease must be applied to the bellows
boot-to-steering gear housing mating surfaces or a leak may occur causing steering gear
damage.
NOTE: On HPAS steering gears, the inner tie-rod retaining washer must be crimped after the inner
tie rod has been tightened.
• When installing, apply grease to the bellows boot-to-steering gear mating surfaces.
• Make sure that the steering gear is in the centered position prior to installing the steering gear.



SECTION 211-04: Steering Column
Manual

Steering column opening trim panel reinforcement bolts 5 - 44
Steering column shaft-to-steering gear bolt 23 - 204
Steering column support bracket nut 21 15 -
Steering wheel nut 35 26 -


Manual
Steering Column
The steering column consists of the following:
• Steering wheel
• Steering column
• Upper and lower steering column shafts
• Steering column switches
• Ignition lock cylinder
The steering column is the mechanical linkage between the steering wheel and the steering gear. The steering
wheel is mounted to a shaft which passes through the center of the steering column. The shaft is centered by
roller ball bearings within the steering column. The steering column shaft then connects the steering column
to the steering gear. The upper and lower steering column shaft connections utilize U-joint type couplings.
The tilt and telescopic functions of the steering column are controlled by a mechanical lever on the underside
of the steering column, which uses a cam to lock and unlock the steering column. When the tilt/telescopic
column lever is unlocked, the steering column can then be adjusted to various positions. The steering column
switches (multifunction and ignition) are mounted to the steering column. These switches are covered by the
upper and lower steering column shrouds.
For steering column switch service information, refer to Section 211-05 .
For ignition lock cylinder service information, refer to Section 501-14 .
Steering Column 4760


Manual
Steering Column
For Electronic Power Assist Steering (EPAS), refer to Section 211-00A .
For Hydraulic Power Assist Steering (HPAS), refer to Section 211-00B .

SECTION 211-04: Steering 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop
Column Manual
Steering Wheel Wrap Bonding
Material
Item Specification
Instant Gel Adhesive WSK-M2G402-A4
TA-19
1. NOTE: If re-adhering leather to the front side of the steering wheel only, it will not be necessary to
remove the steering wheel. Steering wheel removal is necessary only when repairing loose leather on
the backside of the steering wheel.
If necessary remove the steering wheel. For additional information, refer to Steering Wheel in this
section.
2. Position the loose leather out of the way.
3. Apply the specificed adhesive evenly over the wheel spoke.
4. Position the loose leather back into the original position.
5. NOTE: The adhesive should be completely set after 5 minutes. Do not pull on the repair area.
Smooth the leather and tuck in for neat appearance.
• Apply pressure (for at least 30 seconds) until the leather is bonded to the wheel spoke.
6. If removed, Install the steering wheel. For additional information, refer to Steering Wheel in this
section.
Steering Wheel Wrap Bonding 4762

Steering Wheel Wrap Bonding 4763


Manual
REMOVAL AND
INSTALLATION
Steering Wheel

1 3600/ 3F563 Steering wheel (urethane/leather)
2 W711835 Steering wheel nut
3 - Steering wheel switches electrical
connector (part of 3600/3F563)
NOTICE: Do not allow the clockspring to rotate while the steering wheel is disconnected or damage to
the clockspring may result. If there is evidence that the clockspring has rotated, the clockspring must
be recentered. For additional information, refer to Section 501-20B .
1. Position the steering wheel in the straight-ahead position and turn the ignition switch to the OFF
position.
• Remove the key.
2. Remove the driver air bag module. For additional information, refer to Section 501-20B .
3. NOTE: Mark the steering wheel and column shaft for reference during installation.
Remove the steering wheel nut.
4. NOTICE: Do not remove the steering wheel by hitting the shaft with a hammer. Damage to the
column may occur.
Steering Wheel 4764

Using a suitable puller, remove the steering wheel.
• Disconnect the steering wheel switches electrical connector from the clockspring.
• Route the 2 driver air bag module electricalonnectors and harness through the steering wheel.
5. Tape the clockspring center rotor to the outer housing to keep it from rotating.

• Align the steering wheel using the reference mark.
7. Install the driver air bag module. For additional information, refer to Section 501-20B .
Steering Wheel 4765


Manual
REMOVAL AND
INSTALLATION
Steering Wheel Bezel

1 3600 Steering wheel
2 3F910 Center steering wheel bezel
Removal
NOTICE: The center steering wheel bezel is manufactured using plastic wrapped with aluminium and
is very fragile. The removal and installation procedure must be followed exactly as outlined or damage
to the bezel can occur.
NOTICE: Use a plastic trim removal tool or a plastic-coated tool when removing the bezel to avoid
damaging the steering wheel.
2. Using a plastic trim removal tool, carefully separate the bezel from the steering wheel in the following
order:
1. Upper RH corner
2. Lower RH corner
3. Lower LH corner
4. Upper LH corner
3. NOTE: There are a total of 10 pins that secure the bezel to the steering wheel, 4 along the top of the
bezel, 2 along the bottom and 2 on each side in the corners.
Steering Wheel Bezel 4766

Using a plastic trim removal tool, carefully remove the bezel from the steering wheel in the following
order:
1. Top 4 pins
2. RH side 2 pins
3. Bottom 2 pins
4. LH side 2 pins
Installation
NOTICE: Carefully install the bezel onto the steering wheel as instructed or damage to the bezel can
occur.
1. Position the bezel onto the steering wheel and align the 10 pins with their respective holes.
2. NOTE: The bezel is installed in 2 stages. Stage 1 seats the 10 pins into the steering wheel
approximately half-way. Stage 2 fully seats the 10 pins into the steering wheel.
Beginning with the upper RH corner and continuing in a clockwise direction, push the bezel onto the
steering wheel until the pins are seated approximately half-way into the holes.
3. Beginning with the upper RH corner and continuing in a clockwise direction, push the bezel onto the
steering wheel until the pins are fully seated into the holes.
4. Install the driver air bag module. For additional information, refer to Section 501-20B .



Manual
REMOVAL AND
INSTALLATION
Steering Column
Steering Column Wire Harness
NOTE: 2.5L/3.0L shown, 3.5L similar.
Part
1 - Multifunction switch electrical connector (part of
14401)
2 - Ignition switch electrical connector (part of 14401)
3 - Clockspring electrical connector (part of 14401)
4 - Passive Anti-Theft System (PATS) electrical connector
(part of 14401)
5 - Wiring harness retainers (3 required) (part of 14401)
Steering Column Assembly


6 3C529 Steering column
8 N806423 Steering column support bracket nut (4 required)
9 3C611B Steering gear/dash seal
10 3C611A Steering column shaft joint cover
11 W704904 Steering column shaft joint cover nut (2 required)
All vehicles
1. Remove the steering wheel. For additional information, refer to Steering Wheel in this section.
Hybrid vehicles
2. Remove the driver knee air bag module. For additional information, refer to Section 501-20B .
Non-Hybrid vehicles
3. Remove the steering column shroud. For additional information, refer to Steering Column Shroud .
All vehicles
4. Remove the 4 steering column opening trim panel reinforcement bolts and the steering column
opening trim panel reinforcement.
Steering Column Assembly 4770

5. Disconnect the Passive Anti-Theft System (PATS), multifunction switch, ignition switch, clockspring
and steering wheel rotation sensor (3.5L only) electrical connectors.
6. Detach the wiring harness pin-type retainers and position the wiring harness aside.
7. Remove the 2 steering column shaft joint cover nuts.
8. Remove the steering column shaft joint cover.
9. Remove and discard the steering column shaft-to-steering gear bolt.

• To install, tighten the new bolt to 23 Nm (204 lb-in).
10. Disconnect the steering column shaft from the steering gear.
11. Remove the 4 steering column support bracket nuts and the steering column.
• Detach the wire harness pin-type retainer.

• If installing a new steering column, transfer parts as necessary.
Steering Column Assembly 4771


Manual
REMOVAL AND
INSTALLATION
Steering Column Shroud
NOTE: Non-Hybrid vehicle shown, Hybrid vehicle similar.

1 3530 Upper steering column shroud
2 3K512 Lower steering column shroud
3 W707658 Lower steering column shroud screw (3 required)
4 04459 Steering column opening trim panel
Hybrid vehicles
1. Remove the 2 steering column opening trim panel screws.
All vehicles
2. NOTE: The steering column opening trim panel is held in place by retaining clips that clip into the
instrument panel.
Remove the steering column opening trim panel.
• Pull the steering column opening trim panel outward to release the retaining clips.
Fusion and Milan only
3. NOTE: Release the upper steering column shroud by pressing inward on the sides of the shroud and
lifting upwards.
Remove the upper steering column shroud.
4. From the underside of the upper steering column shroud, detach the upper steering column shroud
from the instrument cluster finish panel.
Steering Column Shroud 4772

MKZ
5. NOTE: Release the upper steering column shroud by pressing inward on the sides of the shroud and
lifting upwards.
All vehicles
6. Release the tilt lever, remove the 3 lower steering column shroud screws and then the shroud.
Steering Column Shroud 4773

SECTION 211-05: Steering Column 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop
Switches Manual
Steering Column Switches
The steering column switches consist of the following:
• Multifunction switch
• Ignition switch
The steering column switches receive driver inputs and send signals to various components. The multifunction
switch controls the windshield wipers, hazard flasher, turn signal, headlamp low/high beam and headlamp
dimmer/flash-to-pass. The ignition switch is used in conjunction with the lock cylinder key to start the
vehicle. When the lock cylinder key is switched to different positions, it moves linkages which enable the
ignition switch to send battery voltage to various components.
Steering Column Switches 4774

Switches Manual
Steering Column Switches
Special Tool(s)
Flex Probe Kit



NOTE: The Smart Junction Box (SJB) may also be identified as the Generic Electronic Module (GEM).
The steering column switches include the ignition switch and the multifunction switch (high beam/low beam,
flash-to-pass, turn signal and windshield wiper).
Ignition Switch
The ignition switch is controlled by the ignition lock cylinder with a key. When the ignition cylinder is turned
using the key, a mechanical connection positions the ignition switch to the selected position and allows the
ignition switch to send voltage to specific components. The ignition switch is contained in the steering column
lock module.
Key Removal Inhibit Solenoid
The key removal inhibit solenoid (also known as the key release interlock actuator) is an electronically
controlled solenoid that prevents the ignition lock cylinder from being turned to the OFF position unless the
selector lever is in the PARK position. The key removal inhibit solenoid is part of the ignition switch.
Multifunction Switch
The multifunction switch controls the various components electrically. The multifunction switch is hardwired
to the SJB and controls a ground signal for the high beam, flash-to-pass and turn signal functions. The
multifunction switch is also hardwired to the wiper module and controls a ground signal for the various wiper
and washer functions.
For headlamp and turn signal concerns, refer to Section 417-01 . For wiper and washer concerns, refer to
Section 501-16 .
Steering Column Switches 4775

• Multifunction switch • Smart Junction Box (SJB) fuse 27

• Ignition key (20A)
• Ignition lock cylinder • Wiring, terminals or connectors
• Ignition switch • Ignition switch
• Steering column lock • One-Touch Integrated Start (OTIS)
module diode
• Steering column • SJB
shrouds • PCM
• Park range switch (part of the selector
lever)



418-00 .
(CMDTCs).
8. Clear the continuous DTCs and carry out the self-test diagnostics for the SJB .
9. If the DTCs retrieved are related to the concern, go to Smart Junction Box (SJB) DTC Chart. For all
other DTCs, refer to Section 419-10 .
Multifunction Switch 4776

DTC Chart
Smart Junction Box (SJB) DTC Chart

B2A20 Ignition stuck in START GO to Pinpoint Test F .
B2844 Ignition fault GO to Pinpoint Test G .
U2472 Unexpected Ignition State GO to Pinpoint Test G .
- All Other DTCs REFER to the Master DTC Chart in Section 419-10 .
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: No Power in All Ignition Switch Positions
Refer to Wiring Diagrams Cell 13 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Power Distribution/SJB for
Normal Operation
The ignition switch receives fused battery voltage from Smart Junction Box (SJB) fuse 27 (20A) through
circuit SBP27 (BU/RD). The ignition switch then sends voltage to various systems depending on ignition
switch position. The ignition switch has 4 possible positions:
• OFF - No power on any circuits

• ACC - Power on circuit CDC33 (VT/GN)
• RUN - Power on circuit CDC34 (WH/OG)
• START - Power on circuit CDC35 (BU/WH)

• Fuse
• Ignition switch
• SJB
PINPOINT TEST A: NO POWER IN ALL IGNITION SWITCH POSITIONS
not use standard multimeter probes.
NOTE: Verify that battery voltage is 10 volts or greater.


A1 CHECK AT THE IGNITION SWITCH FOR
tr>
VOLTAGE
Yes
• Ignition OFF. INSTALL a new ignition switch. REFER to
• Disconnect: Ignition Switch C250. Ignition Switch in this section. TEST the system
• Measure the voltage between ignition switch for normal operation.
C250-4, circuit SBP27 (BU/RD), harness side
and ground. No
VERIFY SJB fuse 27 (20A) is OK. If OK, GO to
A2 . If not OK, REFER to the Wiring Diagrams
manual to identify the possible causes of the
circuit short. TEST the system for normal
operation.

A2 CHECK THE IGNITION SWITCH INPUT
CIRCUIT FOR AN OPEN
Yes
• Disconnect: SJB C2280A.
• Measure the resistance between ignition No
switch C250-4, circuit SBP27 (BU/RD), REPAIR circuit SBP27 (BU/RD). TEST the
harness side and SJB C2280A-14, circuit system for normal operation.
SBP27 (BU/RD), harness side.

A3 CHECK FOR CORRECT SJB OPERATION
Yes
• Disconnect: All SJB connectors. INSTALL a new SJB . REFER to Section
• Check the SJB connectors for: 419-10 . TEST the system for normal operation.
♦ corrosion.
♦ pushed-out pins. No
♦ spread terminals. The system is operating correctly at this time.
• Connect: All SJB connectors and make sure The concern may have been caused by a loose or
the connectors seat correctly. corroded connector.
• Operate the system and verify the concern is
still present.
PINPOINT TEST A: NO POWER IN ALL IGNITION SWITCH POSITIONS 4778

Pinpoint Test B: No Power in ACC
Normal Operation
When the ignition switch is placed in the ACC position, fused ignition voltage is sent to the Smart Junction
Box (SJB) through circuit CDC33 (VT/GN).

• Ignition switch
• SJB
PINPOINT TEST B: NO POWER IN ACC

B1 CHECK THE IGNITION SWITCH
Yes
• Disconnect: Ignition Switch C250.
• Carry out the Ignition Switch component test. No
INSTALL a new ignition switch.
Refer to Wiring Diagrams Cell 149 ( Fusion/MKZ , REFER to Ignition Switch in this
Fusion Hybrid/MKZ Hybrid ) for component testing. section. TEST the system for normal
• Did the ignition switch pass the component test? operation.
B2 CHECK THE IGNITION ACC CIRCUIT FOR AN
OPEN
Yes
• Disconnect: SJB C2280A. GO to B3 .
• Measure the resistance between ignition switch C250-6,
circuit CDC33 (VT/GN), harness side and SJB No
C2280A-3, circuit CDC33 (VT/GN), harness side. REPAIR circuit CDC33 (VT/GN).

B3 CHECK THE IGNITION ACC CIRCUIT FOR A
SHORT TO GROUND

• Measure the resistance between ignition switch C250-6, Yes

circuit CDC33 (VT/GN), harness side and ground. GO to B4 .
No
REPAIR circuit CDC33 (VT/GN).

B4 CHECK FOR CORRECT SJB OPERATION
Yes
• Check SJB C2208A for: INSTALL a new SJB . REFER to
♦ corrosion. Section 419-10 . TEST the system for
♦ pushed-out pins. normal operation.
♦ spread terminals.
• Connect: SJB C2280A and make sure the connector is No
seated correctly. The system is operating correctly at this
• Operate the system and verify the concern is still time. Concern may have been caused by
present. a loose or corroded connector.
Pinpoint Test C: No Power in RUN
Normal Operation
When the ignition switch is placed in the RUN position, fused ignition voltage is sent to the Smart Junction
Box (SJB) along circuit CDC34 (WH/OG).

• Ignition switch
• SJB
PINPOINT TEST C: NO POWER IN RUN
NOTE: Verify that battery voltage is greater than 10 volts.

C1 CHECK FOR VOLTAGE ON THE IGNITION RUN
CIRCUIT
PINPOINT TEST B: NO POWER IN ACC 4780


• Disconnect: SJB Fuse 42 (10A) (if equipped). GO to C2 .
• Ignition ON.
• Measure the voltage between SJB fuse 42 (10A), circuit No
CDC34 (WH/OG), input side and ground. GO to C4 .

C2 CHECK FOR VOLTAGE AT THE SJB
Yes
• Ignition OFF. GO to C3 .
• Disconnect: SJB C2280B.
• Ignition ON. No
• Measure the voltage between SJB C2280B-45, circuit GO to C5 .
CDC34 (WH/OG), harness side and ground.

C3 CHECK THE SJB IGNITION SWITCH INPUT
CIRCUIT FOR VOLTAGE
Yes
• Disconnect: SJB C2280E.
• Ignition ON. No
• Measure the voltage between SJB C2280E-1, circuit GO to C6 .
CDC34 (WH/OG), harness side and ground.
PINPOINT TEST C: NO POWER IN RUN 4781


C4 CHECK THE SJB IGNITION SWITCH INPUT
CIRCUIT FOR AN OPEN
Yes
• Disconnect: SJB C2280A.
• Disconnect: Ignition Switch C250. No
• Measure the resistance between ignition switch C250-1, REPAIR circuit CDC34 (WH/OG).
circuit CDC34 (WH/OG), harness side and SJB TEST the system for normal operation.
C2280A-4, circuit CDC34 (WH/OG), harness side.

C5 CHECK THE IGNITION RUN CIRCUIT FOR AN
OPEN
Yes
• Disconnect: Ignition Switch C250. GO to C9 .
circuit CDC34 (WH/OG), harness side and SJB No
C2280B-45, circuit CDC34 (WH/OG), harness side. REPAIR circuit CDC34 (WH/OG).

C6 CHECK THE IGNITION SWITCH OUTPUT
CIRCUIT FOR AN OPEN
Yes
• Disconnect: Ignition Switch C250. GO to C9 .
circuit CDC34 (WH/OG), harness side and SJB No
C2280E-1, circuit CDC34 (WH/OG), harness side. REPAIR circuit CDC34 (WH/OG).


C7 CHECK THE IGNITION RUN CIRCUIT FOR A
SHORT TO GROUND
Yes
• Disconnect: SJB C2280B. GO to C8 .
• Disconnect: SJB C2280E.
• Measure the resistance between ignition switch C250-1, No
circuit CDC34 (WH/OG), harness side and ground. REPAIR circuit CDC34 (WH/OG).

C8 CHECK THE IGNITION SWITCH
Yes
• Carry out the Ignition Switch component test. GO to C10 .
Refer to Wiring Diagrams Cell 149 ( Fusion/MKZ , No

Fusion Hybrid/MKZ Hybrid ) for component testing. INSTALL a new ignition switch.
• Did the ignition switch pass the component test? REFER to Ignition Switch in this
section. TEST the system for normal
operation.
C9 CHECK FOR CORRECT IGNITION SWITCH
OPERATION
Yes
• Carry out the Ignition Switch component test. The system is operating correctly at this
time. The concern may have been
Refer to Wiring Diagrams Cell 149 ( Fusion/MKZ , caused by a loose or corroded
Fusion Hybrid/MKZ Hybrid ) for component testing. connector.
• Did the ignition switch pass the component test?
No
REFER to Ignition Switch in this
operation.
C10 CHECK FOR CORRECT SJB OPERATION
Yes
• Disconnect: All SJB connectors. INSTALL a new SJB . REFER to

• Check the SJB connectors for: Section 419-10 . TEST the system for
♦ corrosion. normal operation.
♦ spread terminals. No
• Connect: All SJB connectors and make sure the The system is operating correctly at this
connectors are seated correctly. time. Concern may have been caused
• Operate the system and verify the concern is still by a loose or corroded connector.
present.
Pinpoint Test D: No Power in START - Non-Hybrid
Normal eration
When the ignition switch is placed in the START position, fused ignition voltage is sent to the PCM and the
One-Touch Integrated Start (OTIS) diode through circuit CDC35 (BU/WH). The voltage passes through the
Battery Junction Box (BJB) OTIS diode and continues to the PCM, starter relay coil and the Smart Junction
Box (SJB) through circuit CE336 (GN/WH).

• Ignition switch
• OTIS diode
• SJB
• PCM
PINPOINT TEST D: NO POWER IN START - NON-HYBRID

D1 CHECK FOR VOLTAGE TO THE BJB
Yes
• Disconnect: BJB OTIS Diode. GO to D5 .
• With the ignition in the START position, measure
the voltage between BJB OTIS diode, circuit No
CDC35 (BU/WH), input side and ground. GO to D2 .
Normal eration 4784


D2 CHECK THE IGNITION START CIRCUIT FOR
AN OPEN
Yes
• Measure the resistance between BJB OTIS diode, No
circuit CDC35 (BU/WH), input side and ignition REPAIR circuit CDC35 (BU/WH). TEST
switch C250-7, circuit CDC35 (BU/WH), harness the system for normal operation.
side.

D3 CHECK THE IGNITION START CIRCUIT FOR
A SHORT TO GROUND
Yes
• Measure the resistance between ignition switch GO to D10 .
C250-7, circuit CDC35 (BU/WH), harness side
and ground. No
GO to D4 .
PINPOINT TEST D: NO POWER IN START - NON-HYBRID 4785


D4 ISOLATE THE PCM FOR A SHORT TO
GROUND
Yes
• Disconnect: PCM C175B. GO to D12 .
• Measure the resistance between ignition switch
C250-7, circuit CDC35 (BU/WH), harness side No
and ground. REPAIR circuit CDC35 (BU/WH). TEST

D5 CHECK THE OTIS DIODE
Yes
• Test the OTIS diode. GO to D6 .
• Is the OTIS diode OK?
No
INSTALL a new OTIS diode. TEST the
D6 CHECK FOR START CIRCUIT VOLTAGE AT
THE PCM
Yes
• Connect: BJB OTIS Diode.
• Disconnect: PCM C175B. No
• With the ignition in the START position, measure REPAIR circuit CDC35 (BU/WH). TEST
the voltage between ground and: the system for normal operation.
♦ 2.5L and 3.0L: PCM C175B-16, circuit
CDC35 (BU/WH), harness side.
♦ 3.5L: PCM C175B-10, circuit CDC35
(BU/WH), harness side.


THE STARTER RELAY
Yes
• Disconnect: BJB Starter Relay. GO to D8 .
• With the ignition in the START position, measure
the voltage between BJB starter relay socket 86, No
circuit CE336 (GN/WH), harness side and ground. REPAIR circuit CE336 (GN/WH). TEST

THE PCM
Yes
• With the ignition in the START position, measure GO to D9 .
the voltage between ground and:
♦ 2.5L and 3.0L: PCM C175B-37, circuit No
CE336 (GN/WH), harness side. REPAIR circuit CE336 (GN/WH). TEST
♦ 3.5L: PCM C175B-19, circuit CE336 the system for normal operation.
(GN/WH), harness side.

D9 CHECK FOR VOLTAGE TO THE SJB
Yes
• With the ignition in the START position, measure No
the voltage between SJB C2280B-32, circuit REPAIR circuit CE336 (GN/WH). TEST
CE336 (GN/WH), harness side and ground. the system for normal operation.


D10 CHECK THE IGNITION SWITCH
Yes
• Carry out the Ignition Switch component test. The system is operating correctly at this
time. Concern may have been caused by a
Refer to Wiring Diagrams Cell 149 ( Fusion/MKZ loose or corroded connector. TEST the
, Fusion Hybrid/MKZ Hybrid ) for component system for normal operation.
testing.
• Did the ignition switch pass the component test? No
INSTALL a new ignition switch. REFER to
Ignition Switch in this section. TEST the
D11 CHECK FOR CORRECT SJB OPERATION
Yes
• Disconnect: All SJB connectors. INSTALL a new SJB . REFER to Section
• Check all SJB connectors for: 419-10 . TEST the system for normal
♦ corrosion. operation.
• Connect: All SJB connectors making sure that all The system is operating correctly at this
connectors are seated correctly. time. Concern may have been caused by a
• Operate the system and verify the concern is still loose or corroded connector.
present.
D12 CHECK FOR CORRECT PCM OPERATION
Yes
• Disconnect: All PCM connectors. INSTALL a new PCM. REFER to Section
• Check all PCM connectors for: 303-14A , Section 303-14B or Section
♦ corrosion. 303-14C . TEST the system for normal
♦ pushed-out pins. operation.
• Connect: All PCM connectors making sure that all No
connectors are seated correctly. The system is operating correctly at this
• Operate the system and verify the concern is still time. Concern may have been caused by a
present. loose or corroded connector.
Pinpoint Test E: No Power in START - Hybrid

Normal Operation
When the ignition switch is placed in the START position, fused ignition voltage is sent to the Smart Junction
Box (SJB) through circuit CDC35 (BU/WH).

• Ignition switch
• SJB
PINPOINT TEST E: NO POWER IN START - HYBRID

E1 CHECK FOR VOLTAGE TO SJB FUSE 28 (5A)
Yes
• Disconnect: SJB Fuse 28 (5A). GO to E4 .
• With the ignition in the START position, measure the voltage
between SJB fuse 28 (5A), circuit CDC35 (BU/WH), input No
side and ground. GO to E2 .

E2 CHECK THE IGNITION START CIRCUIT FOR AN
OPEN
Yes
• Ignition OFF. GO to E3 .
• Measure the resistance between SJB fuse 28 (5A), circuit No
CDC35 (BU/WH), input side and ignition switch C250-7, REPAIR circuit CDC35
circuit CDC35 (BU/WH), harness side. (BU/WH). TEST the system for
normal operation.

E3 CHECK THE IGNITION START CIRCUIT FOR A
SHORT TO GROUND

• Measure the resistance between ignition switch C250-7, Yes

circuit CDC35 (BU/WH), harness side and ground. INSTALL a new ignition switch.
REFER to Ignition Switch in this
section. TEST the system for
normal operation.
No
REPAIR circuit CDC35
(BU/WH). TEST the system for
normal operation.

E4 CHECK FOR CORRECT SJB OPERATION
Yes
• Disconnect: All SJB connectors. INSTALL a new SJB . REFER to
• Check all SJB connectors for: Section 419-10 . TEST the system
♦ corrosion. for normal operation.
• Connect: All SJB connectors making sure that all connectors The system is operating correctly
are seated correctly. at this time. Concern may have
• Operate the system and verify the concern is still present. been caused by a loose or
• Is the concern still present? corroded connector.
Pinpoint Test F: DTC B2A20
Normal Operation
The ignition switch is spring loaded to automatically return to the RUN position after being placed in the
START position. A microprocessor in the Smart Junction Box (SJB) monitors the voltage output from the
ignition switch while the switch is in the START position. This microprocessor is also connected to the Audio
Control Module (ACM) start circuit, so a short to voltage on the ignition switch output circuit or on the ACM
start circuit could cause DTC B2A20 to set.
• B2A20 (Ignition Stuck in START) - The SJB continuously monitors the ignition switch state, if the
SJB receives a START signal for more than 30 seconds, DTC B2A20 will be set.

• Ignition switch
• SJB
• PCM
• ACM
PINPOINT TEST E: NO POWER IN START - HYBRID 4790

PINPOINT TEST F: DTC B2A20

F1 CHECK THE IGNITION SWITCH MECHANICAL
FUNCTION
Yes
• Inspect the ignition switch for correct mechanical GO to F2 .
function. Refer to t Ignition Switch - Mechanical
Component Test in this section. No
• Did the ignition switch pass the component test? INSTALL a new ignition switch. REFER
to Ignition Switch in this section. CLEAR
the DTCs. REPEAT the self-test.
F2 CHECK THE IGNITION SWITCH ELECTRICAL
FUNCTION
Yes
• Ignition OFF. GO to F3 .
• Carry out the Ignition Switch component test. No
INSTALL a new ignition switch. REFER
Refer to Wiring Diagrams Cell 149 ( Fusion/MKZ , to Ignition Switch in this section. CLEAR
Fusion Hybrid/MKZ Hybrid ) for component testing. the DTCs. REPEAT the self-test.
• Did the ignition switch pass the component test?
F3 CHECK THE SJB START POWER OUTPUT
CIRCUIT FOR A SHORT TO VOLTAGE
Yes
• Connect: Ignition Switch C250. GO to F10 .
• Disconnect: SJB Fuse 28 (5A).
• Ignition ON. No
• Measure the voltage between SJB fuse 28 (5A), For non-hybrid vehicles, GO to F4 .
circuit CBP28 (GY/VT), output side and ground.
For hybrid vehicles, GO to F9 .

F4 CHECK THE SJB START POWER INPUT
PINPOINT TEST F: DTC B2A20 4791

• Measure the voltage between SJB fuse 28 (5A), Yes

circuit CE336 (GN/WH), input side and ground. GO to F5 .
No
GO to F13 .

F5 ISOLATE THE SJB START POWER CIRCUIT
Yes
• Disconnect: BJB One-Touch Integrated Start (OTIS)
Diode. No
• Ignition ON. GO to F8 .
• Measure the voltage between SJB fuse 28 (5A),
circuit CE336 (GN/WH), input side and ground.

F6 CHECK THE PCM IGNITION SWITCH INPUT
Yes
• Ignition ON. No
• Measure the voltage between SJB C2280B-32, circuit GO to F13 .
CE336 (GN/WH), harness side and ground.

F7 CHECK THE PCM FOR A SHORT TO VOLTAGE


• Disconnect: PCM C175B. REPAIR circuit CE336 (GN/WH).
• Ignition ON. CLEAR the DTCs. REPEAT the self-test.
• Measure the voltage between SJB C2280B-32, circuit
CE336 (GN/WH), harness side and ground. No
GO to F15 .

F8 CHECK THE IGNITION SWITCH START
POWER OUTPUT CIRCUIT FOR A SHORT TO
VOLTAGE
Yes
• Ignition OFF. REPAIR circuit CDC35 (BU/WH).
• Disconnect: PCM C175B. CLEAR the DTCs. REPEAT the self-test.
• Ignition ON.
• Measure the voltage between BJB OTIS diode, No
circuit CDC35 (BU/WH), input side and ground. GO to F15 .

F9 CHECK THE SJB IGNITION SWITCH INPUT
Yes
• Ignition OFF. REPAIR circuit CDC35 (BU/WH).
• Disconnect: SJB C2280B. CLEAR the DTCs. REPEAT the self-test.
• Ignition ON.
• Measure the voltage between SJB C2280B-32, circuit No
CDC35 (BU/WH), harness side and ground. GO to F13 .


F10 ISOLATE THE ACM
Yes
• Disconnect: ACM C240A.
• Ignition ON. No
• Measure the voltage between SJB fuse 28 (5A), GO to F14 .

F11 ISOLATE THE PCM
Yes
• Disconnect: PCM C175B.
• Ignition ON. No
• Measure the voltage between SJB fuse 28 (5A), GO to F15 .

F12 ISOLATE THE SJB
Yes
• Ignition OFF. REPAIR circuit CBP28 (GY/VT).
• Disconnect: SJB C2280B. CLEAR the DTCs. REPEAT the self-test.
• Ignition ON.
• Measure the voltage between SJB C2280B-2, circuit No
CBP28 (GY/VT), harness side and ground. GO to F13 .


F13 CHECK FOR CORRECT SJB OPERATION
Yes
• Ignition OFF. INSTALL a new SJB . REFER to Section
• Disconnect: All SJB connectors. 419-10 . CLEAR the DTCs. REPEAT the
• Check the SJB connectors for: self-test.
♦ corrosion.
♦ pushed-out pins. No
♦ spread terminals. The system is operating correctly at this
• Connect: All SJB connectors making sure that they time. Concern may have been caused by a
are seated correctly. loose or corroded connector. CLEAR the
• Operate the system and verify the concern is still DTCs. REPEAT the self-test.
present.
F14 CHECK FOR CORRECT ACM OPERATION
Yes
• Disconnect: All ACM connectors. INSTALL a new ACM . REFER to
• Check all ACM connectors for: Section 415-00 . CLEAR the DTCs.
♦ corrosion. REPEAT the self-test.
• Connect: All ACM connectors making sure that all The system is operating correctly at this
connectors are seated correctly. time. Concern may have been caused by a
• Operate the system and verify the concern is still loose or corroded connector. CLEAR the
present. DTCs. REPEAT the self-test.
F15 CHECK FOR CORRECT PCM OPERATION
Yes
• Disconnect: All PCM connectors. INSTALL a new PCM. REFER to
• Check all PCM connectors for: Section 303-14A , Section 303-14B ,
♦ corrosion. Section 303-14C or Section 303-14D .
♦ pushed-out pins. CLEAR the DTCs. REPEAT the self-test.
• Connect: All PCM connectors making sure that all No
connectors are seated correctly. The system is operating correctly at this
• Operate the system and verify the concern is still time. Concern may have been caused by a
present. loose or corroded connector. CLEAR the
• Is the concern still present? DTCs. REPEAT the self-test.
Pinpoint Test G: DTCs B2844 and U2472

Normal Operation
The Smart Junction Box (SJB) contains several inputs that monitor the voltage outputs from the ignition
switch. The SJB uses these inputs to determine the ignition switch position and then sends that information to
various modules over the High Speed Controller Area Network (HS-CAN) bus. The ignition switch is
designed so that only one output (ACC, RUN or START) is sent to the SJB at a time.
• DTC B2844 (Ignition Fault) - If the SJB receives an invalid ignition RUN input or cannot receive the
ignition RUN input during normal operation, DTC B2844 is set.
• DTC U2472 (Unexpected Ignition State) - If the SJB does not receive the ignition RUN signal or
receives conflicting ignition switch signals while performing an on-demand self test, DTC U2472 is
set.

• Ignition switch
• SJB
PINPOINT TEST G: DTCs B2844 AND U2472

G1 CHECK THE SJB DTCs
Yes
• Use the recorded SJB DTCs from the GO to Pinpoint Test F .
continuous and on-demand self tests.
• Is DTC B2A20 present? No
GO to G2 .
G2 CHECK THE IGNITION SWITCH PIDs
Yes
• Connect the scan tool. The condition is not present at this time.
• Ignition ON. INSPECT SJB connectors C2280A and C2280B
• Enter the following diagnostic mode on the for corrosion, spread terminals and/or pushed-out
scan tool: DataLogger - SJB . pins. REPAIR as necessary. CLEAR the DTCs.
• Monitor the following ignition switch PIDs REPEAT the self-test.
while cycling the ignition switch through
each position: No
♦ ECU Derived Ignition State-OFF If IGN_A_ECU is displayed YES at all times,
(IGN_O_ECU) Non-Hybri GO to G3 . Hybrid: GO to G4 .
♦ ECU Derived Ignition State-ACC
(IGN_A_ECU) If IGN_R_ECU is displayed YES at all times, GO
♦ ECU Derived Ignition State-RUN to G6 .
(IGN_R_ECU)
♦ ECU Derived Ignition State-START If IGN_S_ECU displayed YES at all times, GO to
(IGN_S_ECU) Pinpoint Test F .
• Does each PID display YES when the
ignition switch is moved into the If IGN_O_ECU displayed YES at all times, GO to
corresponding position and NO when the Pinpoint Test A .

switch is moved to another position?

If IGN_A_ECU displayed NO at all times, GO to
Pinpoint Test B .
If IGN_R_ECU displayed NO at all times, GO to

Pinpoint Test C .
If IGN_S_ECU displayed NO at all times,

Non-Hybrid: GO to Pinpoint Test D . Hybrid:
GO to Pinpoint Test E .
G3 CHECK SJB FUSE 43 (10A) OUTPUT
Yes
• Ignition OFF. GO to G4 .
• Ignition ON. No
• Enter the following diagnostic mode on the REPAIR circuit CBP43 (GY). CLEAR the DTCs.
scan tool: DataLogger - SJB . REPEAT the self-test.
• Monitor the ignition switch ACC position
PID IGN_A_ECU while cycling the ignition
switch through each position.
• Does the PID display YES when the
ignition switch is moved through all switch
positions?
Yes
• Ignition ON. No
• Enter the following diagnostic mode on the REPAIR circuit CBP45 (YE). CLEAR the DTCs.
• Monitor the ignition switch ACC position
PID IGN_A_ECU while cycling the ignition
positions?
G5 CHECK THE IGNITION SWITCH
Yes
• Ignition OFF. REPAIR circuit CDC33 (VT/GN). CLEAR the
• Disconnect: Ignition Switch C250. DTCs. REPEAT the self-test.
• Carry out the Ignition Switch component
test. No
Refer to Wiring Diagrams Cell 149 ( Ignition Switch in this section. TEST the system
Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ) for normal operation. CLEAR the DTCs.
for component testing. REPEAT the self-test.
• Did the ignition switch pass the
component test?
PINPOINT TEST G: DTCs B2844 AND U2472 4797


• Disconnect: SJB Fuse 44 (10A). GO to G7 .
• Ignition ON.
scan tool: DataLogger - SJB . REPAIR circuit CBP44 (VT). CLEAR the DTCs.
• Monitor the ignition switch RUN position REPEAT the self-test.
PID IGN_R_ECU while cycling the ignition
positions?
Yes
• Ignition ON. No
• Enter the following diagnostic mode on the REPAIR circuit CBP42 (GN). CLEAR the DTCs.
• Monitor the ignition switch RUN position
positions?
Yes
• Ignition ON. No
• Enter the following diagnostic mode on the REPAIR circuit CBP29 (WH/VT). CLEAR the
scan tool: DataLogger - SJB . DTCs. REPEAT the self-test.
ignition ch is moved through all switch
positions?
G9 CHECK SJB FUSE 46 (7.5A) OUTPUT
Yes
• Disconnect: SJB Fuse 46 (7.5A).
• Ignition ON. No
• Enter the following diagnostic mode on the REPAIR circuit CBP46 (WH/BU). CLEAR the
positions?


Yes
• Ignition ON. No
• Enter the following diagnostic mode on the REPAIR circuit CBP36 (BU/BN). CLEAR the
positions?
Yes
• Ignition ON. Enter the following diagnostic No
mode on the scan tool: DataLogger - SJB . REPAIR circuit CBP35 (YE/GY). CLEAR the
• Monitor the ignition switch RUN position DTCs. REPEAT the self-test.
positions?
Yes
• Ignition OFF. For hybrid vehicles, GO G13 .
• Ignition ON. For non-hybrid vehicles, GO to G14 .
scan tool: DataLogger - SJB . No
• Monitor the ignition switch RUN position REPAIR circuit CBP32 (GN/VT). CLEAR the
PID IGN_R_ECU while cycling the ignition DTCs. REPEAT the self-test.
positions?
Yes
• Disconnect: SJB Fuse 37 (10A) (if
equipped). No
• Ignition ON. REPAIR circuit SBP37 (WH). CLEAR the DTCs.
• Enter the following diagnostic mode on the REPEAT the self-test.
scan tool: DataLogger - SJB .


positions?
G14 CHECK THE IGNITION SWITCH RUN
OUTPUT CIRCUIT FOR A SHORT TO
VOLTAGE
Yes
• Disconnect: SJB C2280E. No
• Ignition ON. GO to G16 .
• Measure the voltage between SJB C2280E-1,
circuit CDC34 (WH/OG), harness side and
ground while moving the ignition switch
through all switch positions.
• Is voltage present when the ignition switch

is moved through all switch positions?
G15 CHECK THE IGNITION SWITCH
Yes
• Ignition OFF. REPAIR circuit CDC34 (WH/OG). CLEAR the
• Disconnect: Ignition Switch C250. DTCs. REPEAT the self-test.
• Carry out the Ignition Switch component
test. No
Refer to Wiring Diagrams Cell 149 ( Ignition Switch in this section. CLEAR the DTCs.
Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ) REPEAT the self-test.
for component testing.
• Did the ignition switch pass the
component test?
G16 CHECK FOR CORRECT SJB
OPERATION
Yes
• Ignition OFF. INSTALL a new SJB . REFER to Section 419-10 .
• Disconnect: All SJB connectors. CLEAR the DTC. REPEAT the self-test.
• Check the SJB connectors for:
♦ corrosion. No
♦ pushed-out pins. The system is operating correctly at this time.
♦ spread terminals. Concern may have been caused by a loose or
• Connect: All SJB connectors making sure corroded connector. CLEAR the DTCs. REPEAT
that they are seated correctly. the self-test.
• Make sure the connectors are seated
correctly, then operate the system and verify
the concern is still present.

Pinpoint Test H: The Ignition Key Cannot Be Returned to the OFF Position
Normal Operation
The key removal inhibit solenoid (part of the ignition switch) receives battery voltage from Smart Junction
Box (SJB) fuse 27 (20A) through circuit SBP27 (BU/RD). When the selector lever is moved out of the PARK
position, the park range switch (part of the selector lever) closes and connects circuit CET22 (GY/BN) to
circuit GD116 (BK/VT), providing ground to the key removal inhibit solenoid. The key removal inhibit
solenoid activates and prevents the ignition lock cylinder from being turned to the OFF position and the key
removed.

• Ignition switch
• Ignition lock cylinder
• Selector lever
• Steering column lock module
PINPOINT TEST H: THE IGNITION KEY CANNOT BE RETURNED TO THE OFF POSITION

H1 CHECK FOR AN ENERGIZED KEY
REMOVAL INHIBIT SOLENOID
Yes
• Remove SJB fuse 27 (20A). GO to H4 .
• Attempt to turn the ignition lock cylinder to the
RUN position and then back to the OFF No
position and remove the key. GO to H2 .
• Does the ignition lock cylinder turn to the
OFF position and can the key be removed?
H2 CHECK THE IGNITION SWITCH FOR
MECHANICAL DAMAGE
Yes
• Remove the ignition switch. Refer to Ignition INSTALL a new ignition switch. REFER to
Switch in this section. Ignition Switch in this section. TEST the
• Attempt to turn the ignition lock cylinder to the system for normal operation.
OFF position and remove the ignition key.
• Does the ignition lock cylinder turn to the No
OFF position and can the key be removed? GO to H3 .
H3 CHECK THE IGNITION LOCK CYLINDER
FOR MECHANICAL DAMAGE

• Remove the ignition lock cylinder. Refer to Yes

Section 501-14 . INSTALL a new steering column lock module.
• Rotate the ignition lock cylinder through all REFER to Steering Column Lock Module in
positions using the key. this section. TEST the system for normal
• Does the ignition lock cylinder freely rotate operation.
through all positions and can the key be
removed from the lock cylinder? No
INSTALL a new ignition lock cylinder. REFER
to Section 501-14 . TEST the system for normal
operation.
H4 CHECK THE KEY REMOVAL INHIBIT
SOLENOID CIRCUIT FOR A SHORT TO
GROUND
Yes
• Ignition OFF. INSTALL a new ignition switch. REFER to
• Select PARK. Ignition Switch in this section. TEST the
• Disconnect: Ignition Switch C250. system for normal operation.
C250-3, circuit CET22 (GY/BN), harness side No
and ground. GO to H5 .

H5 ISOLATE THE SHORT TO GROUND IN
THE KEY REMOVAL INHIBIT SOLENOID
CIRCUIT
Yes
• Disconnect: Floor Shifter C3233. INSTALL a new selector lever. REFER to
• Measure the resistance between ignition switch Section 307-05A or Section 307-05B . TEST
C250-3, circuit CET22 (GY/BN), harness side the system for normal operation.
and ground.
No
REPAIR circuit CET22 (GY/BN). TEST the
Pinpoint Test I: The Ignition Key Can Be Turned to the OFF Position When the Selector Lever is Not
in PARK
PINPOINT TEST H: THE IGNITION KEY CANNOT BE RETURNED TO THE OFF POSITION 4802
Normal Operation
The key removal inhibit solenoid (part of the ignition switch) receives battery voltage from Smart Junction
Box (SJB) fuse 27 (20A) through circuit SBP27 (BU/RD). When the selector lever is moved out of the PARK
position, the park range switch (part of the selector lever) closes and connects circuit CET22 (GY/BN) to
circuit GD116 (BK/VT), providing ground to the key removal inhibit solenoid. The key removal inhibit
solenoid activates and prevents the ignition lock cylinder from being turned to the OFF position and the key
removed.

• Ignition switch
• Selector lever
PINPOINT TEST I: THE IGNITION KEY CAN BE TURNED TO THE OFF POSITION WHEN THE SELECTOR LEVER IS
NOT IN PARK

I1 CHECK THE KEY REMOVAL INHIBIT SOLENOID
CIRCUIT FOR GROUND
Yes
• Select NEUTRAL. INSTALL a new ignition switch.
• Disconnect: Ignition Switch C250. REFER to Ignition Switch in this
• Measure the resistance between ignition switch section. TEST the system for normal
C250-3, circuit CET22 (GY/BN), harness side and operation.
ground.
No
GO to I2 .

I2 CHECK THE KEY REMOVAL INHIBIT SOLENOID
CIRCUIT FOR AN OPEN
Yes
• Disconnect: Floor Shifter C3233. GO to I3 .
C250-3, circuit CET22 (GY/BN), harness side and No
floor shifter C3233-2, circuit CET22 (GY/BN), harness REPAIR circuit CET22 (GY/BN).
side. TEST the system for normal operation.


I3 CHECK THE FLOOR SHIFTER GROUND CIRCUIT
FOR AN OPEN
Yes
• Measure the resistance between floor shifter C3233-5, INSTALL a new selector lever. REFER
circuit GD116 (BK/VT), harness side and ground. to Section 307-05A or Section 307-05B
. TEST the system for normal operation.
No
REPAIR circuit GD116 (BK/VT).
Component Tests
Ignition Switch - Mechanical
The following conditions can cause difficulty in operating the ignition switch and lock cylinder:
• Damaged or incorrectly cut ignition key

• Binding ignition lock cylinder
• Binding ignition switch
• Binding or damaged steering column lock module
Carry out the following test to determine if the ignition key/lock cylinder, ignition switch and the steering
column lock module are operating correctly.
1. Inspect the ignition key for any burrs, damage or incorrect cut. Have a new ignition key made as
necessary. If the key is OK, continue with Step 2.
2. Remove the ignition lock cylinder. Refer to Section 501-14 .
3. Rotate the ignition lock cylinder through all of the switch positions.
• If the lock cylinder operates correctly, install the lock cylinder and continue with Step 4.
• If the lock cylinder does not operate correctly, install a new ignition lock cylinder.
4. Remove the ignition switch. Refer to Ignition Switch in this section.
5. Rotate the ignition lock cylinder through all of the switch positions.
• If the lock cylinder operates correctly, install a new ignition switch.
PINPOINT TEST I: THE IGNITION KEY CAN BE TURNED TO THE OFF POSITION WHEN THE
4804
SELECTO
• If the lock cylinder does not operate correctly, install a new steering column lock module.
Refer to Steering Column Lock Module in this section.
PINPOINT TEST I: THE IGNITION KEY CAN BE TURNED TO THE OFF POSITION WHEN THE
4805
SELECTO
Switches Manual
Ignition Switch

4 5404459 Steering column opening cover
6 11572 Ignition switch
NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage
to the column may result.
1. Depower the Supplemental Restraint System (SRS). For additional information, refer to Section
501-20B .
2. NOTE: The steering column opening cover is held in place by tabs that clip to the instrument panel.
Remove the steering column opening cover by pulling straight outward.
3. NOTE: Release the upper steering column shroud, by pressing inward on the sides of the shroud and
lifting upwards.
Ignition Switch 4806

5. NOTE: Lower the steering column to the lowest tilt position.
Disconnect the ignition switch electrical connector.
6. Press the 2 tabs and remove the ignition switch.
8. Repower the SRS . For additional information, refer to Section 501-20B .
Ignition Switch 4807

Switches Manual
Steering Column Multifunction Switch

5 14K147 Multifunction switch
6 - Multifunction switch electrical connector (part of
14401)
7 W503521 Multifunction switch screws (2 required)
lifting upwards.
4. Disconnect the multifunction switch electrical connector.
5. Remove the 2 multifunction switch screws and the switch.
Steering Column Multifunction Switch 4808

Steering Column Multifunction Switch 4809

Switches Manual
Steering Column Lock Module
Part
5 12049 Steering column lock module bolt (2 required)
6 - Steering column lock module clamp (part of 3K772)
7 3K772 Steering column lock module assembly
8 - Passive Anti-Theft System (PATS) electrical connector
(part of 14401)
lifting upwards.
Steering Column Lock Module 4810

4. Disconnect the Passive Anti-Theft System (PATS) and ignition switch electrical connectors.
5. Disconnect the multifunction switch electrical connector.
6. NOTE: After cutting slots in the lock module bolts, clean all metal shavings and foreign material
from the steering column.
Using a suitable tool, cut slots into the heads of the 2 steering column lock module bolts.
7. NOTE: The lock module bolts are designed to sheer off when tightened.
Remove the 2 steering column lock module bolts using a screwdriver.
• Discard the bolts.

• To install, use new steering column lock module bolts and tighten until the heads of the bolts
shear off.
8. Remove the steering column lock module clamp and the steering column lock module assembly.
9. NOTE: Align the locating tab on the steeriumn lock module with the window of the steering column
tube. Verify that the lock module operates correctly.

SECTION 412-00A: Climate Control System - General 2012 Fusion, MKZ, Fusion Hybrid,
Information and Diagnostics MKZ Hybrid Workshop Manual
Material

A/C Cooling Coil Coating - -
YN-29
A/C System Flushing - -
Solvent
YN-23
Motorcraft® Electric A/C -
Hybrid vehicles
Compressor Oil only
YN-32 130 ml
(4.4 fl oz)
PAG Refrigerant WSH-M1C231-B Non-hybrid
Compressor Oil (R-134a vehicles only
Systems) 177 ml
YN-12-D (6 fl oz)
R-134a Refrigerant WSH-M17B19-A 0.62 kg
YN-19 (US); CYN-16-P or (22 oz)
CYN-16-R (Canada) (1.38 lb)
Specification
A/C Compressor (Non-Hybrid)
Type SP17
A/C Compressor Magnetic Clutch
Air gap clearance 0.3-0.6 mm
(0.012-0.024 in)
A/C Pressure Relief Valve a
Close pressure 3103 kPa (450 psi)

Open pressure 3,792-4,137 kPa
(550-600 psi)
Evaporator Discharge Air Temperature Sensor
OFF temperature 2°C (36°F)
ON temperature 3°C (37°F)
Refrigerant System Dye
R-134a Leak Detection Dye 164-R6060 or 164-R6081 -
a Manifold gauge set pressures may vary slightly depending on the distance between the service gauge port
valve and the A/C pressure relief valve, the A/C cycling switch or the pressure cutoff switch location.


SECTION 412-00A: Climate Control System - General 2012 Fusion, MKZ, Fusion Hybrid,
Information and Diagnostics MKZ Hybrid Workshop Manual
Climate Control System
WARNING: Take the following precautions when repairing an air conditioning system containing
R-134a:
♦ Always wear safety goggles.

♦ Avoid contact with liquid refrigerant R-134a. R-134a vaporizes at approximately -25°C (-13°F) under
atmospheric pressure and will freeze skin tissue.
♦ Never allow refrigerant R-134a gas to escape in quantity in an occupied space. It will displace the
oxygen needed to support life.
♦ Never use a torch in an atmosphere containing R-134a gas. R-134a is non-toxic at all normal
conditions, but it decomposes when exposed to high temperatures such as a torch flame. During
decomposition it releases irritating and toxic gasses (as described in the MSDS sheet from the
manufacturer). Decomposition products are hydrofluoric acid, carbon dioxide and water.
Failure to follow theseuctions may result in serious personal injury.
NOTICE: To avoid damaging the vehicle or Air Conditioning (A/C) components, the following
precautions must be observed.
• The A/C refrigerant of all vehicles must be identified and analyzed prior to refrigerant charging.
Failure to do so can contaminate the shop bulk refrigerant and other vehicles.
• Do not add R-12 refrigerant to an A/C system that requires the use of R-134a refrigerant. These 2
types of refrigerant must never be mixed. Doing so can damage the A/C system.
• Charge the A/C system with R-134a refrigerant gas while the engine is running only at the
low-pressure side to prevent refrigerant slugging from damaging the A/C compressor.
• Use only R-134a refrigerant. Due to environmental concerns, when the A/C system is drained, the
refrigerant must be collected using refrigerant recovery/recycling equipment. Federal, State/Provincial
and/or local laws REQUIRE that R-134a be recovered into appropriate recovery equipment and the
process be conducted by qualified technicians who have been certified by an approved organization,
such as Automotive Service Excellence (ASE) or Mobile Air Conditioning Society (MACS). Use of a
recovery machine dedicated to R-134a is necessary to reduce the possibility of oil and refrigerant
incompatibility concerns. Refer to the instructions provided by the equipment manufacturer when
removing refrigerant from or charging the A/C system.
• Refrigerant R-134a must not be mixed with air for leak testing or used with air for any other purpose
above atmospheric pressure. R-134a is combustible when mixed with high concentrations of air and
higher pressures.
• A number of manufacturers are producing refrigerant products that are described as direct substitutes
for refrigerant R-134a. The use of any unauthorized substitute refrigerant can severely damage the
A/C components. If repair is required, use only new or recycled refrigerant R-134a.
NOTICE: To avoid contamination of the Air Conditioning (A/C) system, the following precautions must
be observed.
• Never open or loosen a connection before recovering the refrigerant.

• When loosening a connection, if any residual pressure is evident, allow it to leak out before opening
the fitting.
• Evacuate a system that has been opened to install a new component or one that has discharged
through leakage before charging.
• Seal open fittings with a cap or plug immediately after disconnecting a component from the system.
Climate Control System 4814

• Clean the outside of the fittings thoroughly before disconnecting a component from the system.
• Do not remove the sealing caps from a new component until ready to install.
• Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open an oil
container until ready to use and install the cap immediately after using. Store the oil in a clean,
moisture-free container.
• Install a new O-ring seal before connecting an open fitting. Coat the fitting and O-ring seal with PAG
oil before connecting.
• When installing a refrigerant line, avoid sharp bends. Position the line away from the exhaust or any
sharp edges that can chafe the line.
• Tighten threaded fittings only to specifications. The steel and aluminum fittings used in the refrigerant
system will not tolerate overtightening.
• When disconnecting a fitting, use a wrench on both halves of the fitting to prevent twisting of the
refrigerant lines or tubes.
• Do not open a refrigerant system or uncap a new component unless it is as close as possible to room
temperature. This will prevent condensation from forming inside a component that is cooler than the
surrounding air.
The Electronic Manual Temperature Control (EMTC) system heats or cools the vehicle depending on the
HVAC module - control panel selection.
• The control panel selectiondetermine heating or cooling, air distribution and enables blower motor
operation.
• The temperature control setting determines the air temperature.
• The blower motor switch varies the blower motor speed.
• During A/C operation, the system also reduces the relative humidity of the air.
The Dual Automatic Temperature Control (DATC) system maintains the selected vehicle interior temperature
by heating and/or cooling the air.
• The driver may override the automatic mode of operation.
• The blower motor control override buttons vary the blower motor speed.
• The driver side and passenger side temperature settings can be individually controlled.
The system consists of the following components:
• A/C compressor
• A/C compressor clutch assembly
• A/C condenser core
• A/C evaporator core
• Receiver/drier
• Connecting refrigerant lines
• Thermostatic Expansion Valve (TXV)
• A/C pressure transducer
• Heater core and evaporator core housing
• HVAC module
• Front Controls Interface Module (FCIM) (Fusion with navigation and all MKZ)
• Audio Control Module (ACM) (all vehicles equipped with navigation systems)
• Temperature blend door actuators
• Defrost/panel/floor mode door actuator
• Air inlet mode door actuator
• Blower motor resistor ( EMTC systems only)
• Blower motor speed control ( DATC systems only)

• Blower motor
• Ambient air temperature sensor
• In-vehicle temperature sensor ( DATC systems only)
• Sunload sensor ( DATC systems only)
• Evaporator temperature sensor
Electronic Manual Temperature Control (EMTC) System
The EMTC system heats or cools the vehicle depending on the control panel selection.
• The control panel selections determine heating or cooling, air distribution and enables blower motor
operation.
• The blower motor switch varies the blower motor speed.
• During A/C operation the system also reduces the relative humidity of the air.
The EMTC system operation is determined by the settings on the climate controls. To control the various
functions, the EMTC system is composed of the following:
• HVAC module
• Blower motor resistor
• Temperature blend door actuator
The blower motor switch:
• sets the blower motor speed.

• is serviced only with the HVAC module.
The A/C request button:
• can command the A/C compressor ON when the function selector switch is in PANEL,
FLOOR/PANEL, FLOOR/DEFROST and FLOOR when the A/C request switch is pressed. Indicator
illuminates when A/C request switch is toggled ON.
• indicator illuminates when the function selector switch is in MAX A/C and cannot be toggled.
The function selector:
• selects airflow direction.

The temperature selector:
• selects full warm and full cool as well as blended outlet temperatures.
The air recirculation button:
• selects either recirculated or outside air source.

• recirculates air in any mode except DEFROST, if requested.
• is disabled in MAX A/C or OFF mode where recirculated air only is used.
• is disabled in DEFROST mode where outside air only is used.
Dual Automatic Temperature Control (DATC) System
NOTE: For the passenger side temperature setting on hybrid vehicles equipped with dual-zone Electronic
Automatic Temperature Control (EATC) and a Front Controls Interface Module (FCIM) built on or after
04/08/2009 to be functional, a passenger must be seated in the front passenger seat. If the front passenger seat
is not occupied, the HVAC module will control the system based only on the driver side temperature setting.
The HVAC module receives a Medium Speed Controller Area Network (MS-CAN) signal from the FCIM to
indicate if the front passenger seat is occupied.
The DATC system maintains the selected vehicle interior temperature by heating and/or cooling the air.
• The driver may override the automatic mode of operation.
• The temperature control setting determines the desired air temperature.
• The blower motor control override button varies the blower motor speed.
• The driver side and passenger side temperature settings can be individually controlled.
The DATC system operation is determined by the settings on the climate controls. The HVAC system
automatically maintains a selected temperature for vehicle interior comfort. To control the various functions,
the DATC system is composed of the following:
• HVAC module
• Front Controls Interface Module (FCIM) (Fusion with navigation and all MKZ)
• Blower motor speed control
• LH and RH temperature blend door actuators
• In-vehicle temperature sensor
• Sunload sensor
When the DATC system is set to AUTO:
• the air distribution direction, blower motor speed and A/C compressor operation are automatically
controlled based on the temperature(s) selected.
The DATC system manual override settings:
• allow the air distribution direction to be manually selected.

• allow the blower motor speed to be manually selected.
• allow recirculation mode to be manually selected in all modes except DEFROST. The A/C request
can be cancelled by pressing the A/C request switch, turning the indicator OFF.
• allow A/C compressor operation to be manually selected except in DEFROST.
External Temperature Display

While the actual external temperature can vary continuously, the value that is displayed will update at a
specific rate depending on whether or not the engine is "hot" and whether or not the vehicle is moving.
When the external temperature is rising, the display will update slowly.
Updates (when the actual external temperature is higher than currently displayed value) will be limited to
0.6°C (1°F) every 20 seconds while the vehicle is moving at greater than 40 km/h (25 mph) for more than 90
seconds or 0.6°C (1°F) every 20 minutes if the vehicle is not moving at this speed. This is to prevent the heat
from the engine compartment from affecting the accuracy of the display.
When the external temperature is dropping, the display will update quickly.
Updates (when the actual external temperature is lower than currently displayed value) will only be limited to
0.6°C (1°F) every 2 seconds (regardless of vehicle speed). Consequently the display will essentially follow the
drop ienced by the external temperature thermistor.
System Airflow Description - Electronic Manual Temperature Control (EMTC)
Max A/C
When MAX A/C is selected:
• the air inlet mode door actuator closes off outside air and admits only recirculated air.
• the RECIRC button is disabled and the indicator is illuminated.
• the defrost/panel/floor mode door directs airflow to the instrument panel A/C registers.
• blended air temperature is available.
• the A/C request button is illuminated and will be disabled.
• the A/C compressor will operate if the outside temperature is above approximately 6°C (43°F).
• the blower motor is ON.
PANEL
When PANEL is selected:
• the RECIRC request button is enabled. If the RECIRC request button is selected (indicator ON), the
air inlet door actuator closes off outside air from entering the passenger compartment. If the RECIRC
request button is not selected (indicator OFF), the air inlet mode door actuator admits only outside air
into the passenger compartment.
• the A/C request button is enabled. The A/C compressor can operate and the indicator will illuminate if
the A/C request button is selected and the outside temperature is above approximately 6°C (43°F).
PANEL/FLOOR
When PANEL/FLOOR is selected:
into the passenger compartment. the defrost/panel/floor mode door directs airflow to the floor duct
and the instrument panel A/C registers. A small amount of airflow from the side window demisters

and defrost duct will be present.

OFF
When OFF is selected:
• the air inlet door actuator closes off outside air and admits only recirculated air.
• the blower motor is OFF.
FLOOR
When FLOOR is selected:
into the passenger compartment.
• the defrost/panel/floor mode door directs airflow to the floor duct. A small amount of airflow from the
defroster duct and side window demisters will be present.
FLOOR/DEFROST
When the FLOOR/DEFROST is selected:
air inlet mode door actuator closes off outside air from entering the passenger compartment. If the
RECIRC request button is not selected (indicator OFF), the air inlet mode door actuator admits only
outside air into the passenger compartment.
• therost/panel/floor mode door directs airflow to the floor duct, the defroster duct and the side window
demisters.
• the A/C request button will indicate the last status and the indicator can be toggled. To reduce
fogging, the A/C compressor will operate automatically, regardless of indicator status, if the outside
temperature is above approximately 6°C (43°F).
DEFROST
When DEFROST is selected:
• the air inlet mode door actuator opens, admitting only outside air into the passenger compartment.
• the defrost/panel/floor mode door directs airflow to the defroster duct and side window demisters. A
small amount of airflow from the floor duct will be present.


System Airflow Description - Dual Automatic Temperature Control (DATC)
AUTO
When AUTO is selected:
• the temperature control setting is manually set to the desired setting.

• the air inlet mode door actuator is automatically controlled by the HVAC module, based on the
temperature setting.
• the door actuators are automatically controlled by the HVAC module, based on the temperature
setting.
• the A/C compressor is automatically controlled by the HVAC module, based on the temperature
setting. The A/C compressor will not operate if the outside temperature is below approximately 6°C
(43°F).
• the A/C request button or the RECIRC request button, if pressed, will transfer the system to semi-auto
operation.
• the blower motor he blower motor speed is automatically controlled by the HVAC module, based on
the temperature setting, but can be manually overridden.
OFF
When OFF is selected:
• the air inlet door actuator closes off outside air and admits only recirculated air.
• the blower motor is OFF.
PANEL
When PANEL is selected:
• blended air temperature is available. Only when A/C compressor operation has been selected by
pressing the A/C request button (indicator ON), can the airflow temperature be cooled below the
outside air temperature.
PANEL/FLOOR
When PANEL/FLOOR is selected:

• the defrost/panel/floor mode door directs airflow to the floor duct and the instrument panel A/C
registers. A small amount of airflow from the side window demisters and defrost duct will be present.
• blended air temperature is available. Only when A/C mpressor operation has been selected by
FLOOR
When FLOOR is selected:
• the defrost/panel/floor mode door directs airflow to the floor duct. A small amount of airflow from the
defroster duct and side window demisters will be present.
• blended air temperature is available. Only when A/C compressor operation has been selected by
FLOOR/DEFROST
When the FLOOR/DEFROST is selected:
• the defrost/panel/floor mode door directs airflow to the floor duct, the defroster duct and the side
window sters.
• the A/C request button is enabled. The A/C compressor will operate automatically and the indicator
will illuminate if the A/C request button is selected and the outside temperature is above
approximately 6°C (43°F).
DEFROST
When DEFROST is selected:
• the RECIRC request button and indicator is disabled. Regardless of button and indicator status, the air
inlet mode door actuator admits only outside air into the passenger compartment.
• the defrost/panel/floor mode door directs airflow to the defroster duct and side window demisters. A
small amount of airflow from the floor duct will be present.


SECTION 412-00A: Climate Control System â 2012 Fusion, MKZ, Fusion Hybrid, MKZ
General Information and Diagnostics Hybrid Workshop Manual
Special Tool(s)
A/C Flush Adapter Kit

Flex Probe Kit


Heated Pentode Halogen Leak Detector

Pressure Test Kit

R-134a Manifold Gauge Set

176-R032A or equivalent
Test Light
SGT27000 or equivalent 250-300 mA
incandescent bulb test lamp
There are 4 main principles involved with the basic theory of operation:
• Heat transfer
• Latent heat of vaporization
• Relative humidity
• Effects of pressure
Heat Transfer
If 2 substances of different temperature are placed near each other, the heat in the warmer substance will
transfer to the colder substance.
Latent Heat of Vaporization

When a liquid boils (converts to gas), it absorbs heat without raising the temperature of the resulting gas.
When the gas condenses (converts back to a liquid), it gives off heat without lowering the temperature of the
resulting liquid.
Relative Humidity
The amount of moisture (water vapor content) that the air can hold is directly related to the air temperature.
The more heat there is in the air, the more moisture the air can hold. The lower the moisture content in the air,
the more comfortable occupants feel. Removing the moisture from the air lowers its relative humidity and
improves personal comfort.
Effects of Pressure on Boiling or Condensation
As the pressure is increased on a liquid, the temperature at which the liquid boils (converts to gas) also
increases. Conversely, when the pressure on a liquid is reduced, its boiling point is also reduced. When in the
gas state, an increase in pressure causes an increase in temperature, while a decrease in pressure will decrease
the temperature of the gas.
Compressor Anti-Slugging Strategy (CASS)
Liquid refrigerant may accumulate in the A/C compressor under certain conditions. To alleviate damage to the
A/C compressor, Compressor Anti-Slugging Strategy (CASS) is utilized.
CASS is initiated only under specific conditions:
• The ignition is off for more than 8 hours

• The ambient temperature is above -4Â°C (25Â°F)
• Battery voltage is above 8.5 volts during engine cranking
When these conditions are present, the PCM will activate the A/C control relay prior to cranking of the
engine. The A/C control relay engages the A/C compressor for approximately 4-15 A/C compressor
revolutions or a maximum of 2 seconds (depending upon vehicle application), allowing the liquid refrigerant
to be pushed from the A/C compressor. CASS is initiated by the PCM regardless of the system settings.
The Refrigerant Cycle
During stabilized conditions (A/C system shutdown), the refrigerant pressures are equal throughout the
system. When the A/C compressor is in operation, it increases pressure on the refrigerant vapor, raising its
temperature. The high-pressure and high-temperature vapor is then released into the top of the A/C condenser
core.
The A/C condenser, being close to ambient temperature, causes the refrigerant vapor to condense into a liquid
when heat is removed from the refrigerant by ambient air passing over the fins and tubing. The now liquid
refrigerant, still at high pressure, exits from the bottom of the A/C condenser and enters the inlet side of the
A/C receiver/drier. The receiver/drier is designed to remove moisture from the refrigerant.
The outlet of the receiver/drier is connected to the Thermostatic Expansion Valve (TXV). The TXV provides
the orifice which is the restriction in the refrigerant system and separates the high and low pressure sides of
the A/C system. As the liquid refrigerant passes across this restriction, its pressure and boiling point are
reduced.
The liquid refrigerant is now at its lowest pressure and temperature. As it passes through the A/C evaporator,

it absorbs heat from the airflow passing over the plate/fin sections of the A/C evaporator. This addition of heat
causes the refrigerant to boil (convert to gas). The now cooler air can no longer support the same humidity
level of the warmer air and this excess moisture condenses on the exterior of the evaporator coils and fins and
drains outside the vehicle.
The refrigerant cycle is now repeated with the A/C compressor again increasing the pressure and temperature
of the refrigerant.
A thermistor which monitors the temperature of the air that has passed through the evaporator core controls
A/C clutch cycling. If the temperature of the evaporator core discharge air is low enough to cause the
condensed water vapor to freeze, the A/C clutch is disengaged by the vehicle PCM.
The high-side line pressure is also monitored so that A/C compressor operation will be interrupted if the
system pressure becomes too high or is determined to be too low (low charge condition).
The A/C compressor thermal protection switch will interrupt compressor operation if the compressor housing
exceeds temperature limits.
The A/C compressor relief valve will open and vent refrigerant to relieve unusually high system pressure.
Thermostatic Expansion Valve (TXV) Type Refrigerant System
Item Description
1 A/C evaporator core
2 A/C evaporator core temperature sensor
Thermostatic Expansion Valve (TXV) Type Refrigerant System 4825

3 Thermostatic Expansion Valve (TXV)

4 A/C charge valve port (low side)
5 A/C suction line
6 A/C compressor
7 A/C pressure relief valve
8 A/C pressure transducer
9 Low-pressure vapor
10 High-pressure vapor
11 Low-pressure liquid
12 High-pressure liquid
13 Compressor discharge line
14 A/C desiccant cartridge
15 A/C condenser core with A/C receiver/drier
16 Condenser-to-evaporator line
17 A/C charge valve port (high side)
1. Verify the customer's concern by operating the climate control system to duplicate the condition.
2. Inspect to determine if one of the following mechanical or electrical concerns apply:
• Loose, missing or damaged A/C compressor • Battery Junction Box
drive belt (BJB) fuse:
• Loose or disconnected A/C clutch ♦ 25 (10A)
• Broken or binding door/actuator ♦ 35 (40A)
• Broken or leaking refrigerant lines ♦ 47 (10A)
• Obstructed in-vehicle temperature sensor • Smart Junction Box (SJB)
• Disconnected in-vehicle temperature aspirator fuse:
hose ♦ 15 (10A)
♦ 45 (5A)
• Blower motor inoperative
• A/C compressor
inoperative
• Circuitry open/shorted
• Disconnected electrical
connectors
• Cooling fan inoperative
3. If the inspection reveals obvious concerns that can be readily identified, repair as necessary.

5. NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground


• refer to Section 418-00 to diagnose no response from the PCM, HVAC module.

418-00 .
• If the network test passes, retrieve and record the Continuous Memory Diagnostic Trouble
Codes (CMDTCs).
8. Clear the continuous DTCs and carry out the self-test diagnostics from the PCM or HVAC module.
9. NOTE: Some PCM DTCs may inhibit A/C operation. If any PCM DTCs are retrieved, diagnose
those first. Refer to the PCM DTC Chart.
If the HVAC DTCs retrieved are related to the concern, go to the HVAC Module DTC Chart. If the
PCM DTCs retrieved are related to the concern, go to the PCM DTC Chart. For all other DTCs, refer
to Section 419-10 .
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - Climate Control Systems or
GO to Symptom Chart - NVH .
DTC Charts
PCM DTC Chart
DTC Description Action to Take

P0532 A/C Pressure GO to Pinpoint Test A .
Refrigerant Sensor A
Circuit Low
P0533 A/C Refrigerant GO to Pinpoint Test A .
Pressure Sensor A
Circuit High
P0645 Air Conditioning GO to Pinpoint Test B .
Clutch Relay
(A/CCR) Control
Circuit
P1464 A/C Demand Out Of If the HVAC selector was not in the OFF position, place it in the OFF
Self Test Range position, CLEAR the DTCs and REPEAT the self-test. If the DTC does not
return, ignore the DTC and continue diagnostics. If the DTC returns,
INSTALL a new HVAC module. CLEAR the DTCs and REPEAT the

self-test.
All â REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Other
DTCs
HVAC Module DTC Chart
NOTE: This module utilizes a 5-character DTC followed by a 2-character failure type code. The failure type
code provides information about specific fault conditions such as opens or shorts to ground. Continuous
Memory Diagnostic Trouble Codes (CMDTCs) have an additional 2-character DTC status code suffix to
assist in determining DTC history.
NOTE: Some PCM DTCs may inhibit A/C operation. If any PCM DTCs are retrieved, diagnose those first.
Refer to the PCM DTC Chart.

B1081:07 Left Temperature Damper GO to Pinpoint Test P .
Motor: Mechanical Failure
Motor: Circuit Short to
Ground
Battery
Motor: Circuit Open
B1082:07 Right Temperature Damper GO to Pinpoint Test P .
Ground
Battery
Motor: Circuit Open
B1083:11 Recirculation Damper GO to Pinpoint Test J .
Ground
Battery
Motor: Circuit Open
B1086:07 Air Distribution Damper GO to Pinpoint Test K .
Motor: Mechanical Failures
B1086:11 GO to Pinpoint Test K .

Air Distribution Damper

Ground
Battery
Motor: Circuit Open
B10AF:12 Blower Fan Relay: Circuit Electronic Manual Temperature Control (EMTC) systems, GO to
Short to Battery Pinpoint Test Q .
Dual Automatic Temperature Control (DATC) systems, GO to

Pinpoint Test S .
B10AF:14 Blower Fan Relay: Circuit For EMTC systems, if the blower motor is inoperative, GO to
Short to Ground or Open Pinpoint Test Q .
For EMTC systems, if the blower motor is always on, GO to

Pinpoint Test R .
For DATC systems, if the blower motor is inoperative, GO to

Pinpoint Test S .
For DATC systems, if the blower motor relay is always on, GO to

Pinpoint Test T .
B10B8:00 Push Buttons: No Sub Type Without navigation, button held too long may set DTC.
Information ATTEMPT to clean buttons. CLEAR the DTCs. REPEAT the
self-test. If code returns, INSTALL a new HVAC module.
With navigation, button held too long may set DTC. ATTEMPT
to clean buttons. CLEAR the DTCs. REPEAT the self-test. If code
returns, INSTALL a new Front Controls Interface Module
(FCIM).
B10B9:12 Blower Control: Circuit GO to Pinpoint Test S .
Short to Battery
B10B9:14 Blower Control: Circuit If the blower motor is inoperative, GO to Pinpoint Test S .
Short to Ground or Open
If the blower motor is always on or operates incorrectly, GO to
Pinpoint Test T .
B11E5:11 Left HVAC Damper Position GO to Pinpoint Test P .
Sensor: Circuit Short to
Ground
B11E5:15 Left HVAC Damper Position GO to Pinpoint Test P .
Battery or Open
B11E6:11 Right HVAC Damper GO to Pinpoint Test P .
Position Sensor: Circuit
Short to Ground
B11E6:15 Right HVAC Damper GO to Pinpoint Test P .
Short to Battery or Open
B11E7:11 GO to Pinpoint Test K .

Air Distribution Damper

Short to Ground
B11E7:15 Air Distribution Damper GO to Pinpoint Test K .
B1A61:11 Cabin Temperature Sensor: GO to Pinpoint Test D .
Circuit Short to Ground
B1A61:15 Cabin Temperature Sensor: GO to Pinpoint Test D .
Circuit Short to Battery or
Open
B1A63:11 Right Solar Sensor: Circuit GO to Pinpoint Test F .
Short to Ground
B1A63:15 Right Solar Sensor: Circuit GO to Pinpoint Test F .
B1A64:11 Left Solar Sensor: Circuit GO to Pinpoint Test F .
Short to Ground
B1A64:15 Left Solar Sensor: Circuit GO to Pinpoint Test F .
B1A68:11 Ambient Temperature GO to Pinpoint Test E .
Ground
B1A68:15 Ambient Temperature GO to Pinpoint Test E .
Battery or Open
B1B71:11 Evaporator Temperature GO to Pinpoint Test G .
Ground
B1B71:15 Evaporator Temperature GO to Pinpoint Test G .
Battery or Open
C1B14:11 Sensor Supply Voltage A: GO to Pinpoint Test C .
C1B14:12 Sensor Supply Voltage A: GO to Pinpoint Test C .
Circuit Short to Battery
U0140:00 Lost Communication With REFER to Section 418-00 to diagnose lost communication with
Body Control Module: No the Smart Junction Box (SJB).
Sub Type Information
Instrument Panel Cluster the IPC module.
(IPC) Module: No Sub Type
Information
navigation Control Module: the Audio Control Module (ACM).
No Sub Type Information
Front Controls Interface the FCIM .
Module (FCIM) "A": No Sub
Type Information
U0422:68

Invalid Data Received From This DTC can set due to a fault in the SJB or because the SJB is
Body Control Module: Event unable to communicate over the Controller Area Network (CAN)
Information bus. CARRY OUT a self-test of the SJB . If the scan tool indicates
that the SJB is not responding, REFER to Section 418-00 to
diagnose the network communication concern. If SJB DTCs are
present, REFER to Section 419-10 .
U0423:68 Invalid Data Received From This DTC can set due to a fault in the IPC or because the IPC is
Instrument Panel Cluster unable to communicate over the CAN bus. CARRY OUT a
Control Module: Event self-test of the IPC . If the scan tool indicates that the IPC is not
Information responding, REFER to Section 418-00 to diagnose the network
communication concern. If IPC DTCs are present, REFER to
Section 413-01 to diagnose the IPC system fault
U0557:68 Invalid Data Received From This DTC can set due to a fault in the FCIM or because the FCIM
Front Controls Interface is unable to communicate over the CAN bus. CARRY OUT a
Module (FCIM) "A": Event self-test of the FCIM . If the scan tool indicates that the FCIM is
Information not responding, REFER to Section 418-00 to diagnose the network
communication concern. If FCIM DTCs are present, REFER to
Section 415-00 to diagnose the FCIM fault
U1000:00 Solid State Driver Protection INSTALL a new HVAC module. REFER to Section 412-01 .
Activated-Driver Disabled:
U2100:00 Initial Configuration Not INSTALL a new HVAC module. REFER to Section 412-01 .
Complete: No Sub Type
Information
U3000:41 Control Module: General INSTALL a new HVAC module. REFER to Section 412-01 .
Checksum Failure
U3002:62 Vehicle Identification INSTALL a new HVAC module. REFER to Section 412-01 .
Number: Signal Compare
Failure
U3003:16 Battery Voltage: Circuit GO to Pinpoint Test H .
Voltage Below Threshold
Voltage Above Threshold
All Other â REFER to the Master DTC Chart in Section 419-10 .
DTCs
Symptom Chart â Climate Control Systems
Symptom Chart â Climate Control Systems

• No communication with the HVAC module
• Fuse(s)
• Circuitry open
• HVAC module communication network

• REFER to Section 418-00 .
• Unable to duplicate the customer concern and no DTCs present
• HVAC system and/or related components
• GO to Pinpoint Test I .
• Reduced outlet airflow
• Circuitry short
• A/C compressor clutch air gap
• A/C cycling switch
• A/C clutch relay
• Blower motor
• Blower motor control
• Blower motor switch
• PCM
• If the A/C compressor does not cycle, GO to Pinpoint Test N .

• For Electronic Manual Temperature Control (EMTC) systems, if the A/C compressor cycles
normally, GO to Pinpoint Test R .
• For Dual Automatic Temperature Control (DATC) systems, if the A/C compressor cycles normally,
GO to Pinpoint Test T .
• The air inlet door is inoperative
• Door actuator
• Air inlet door binding or stuck
• HVAC module
• GO to Pinpoint Test J .
• Incorrect/erratic direction of airflow from outlets
• Door actuator
• Mode door binding or stuck
• HVAC module
• GO to Pinpoint Test K .
• Insufficient, erratic or no heat
• Low engine coolant level

• Engine overheating
• Plugged or partially plugged heater core
• Temperature blend door is binding or stuck
• Heater hose is kinked or binding
• GO to Pinpoint Test L .

• The air conditioning (A/C) is inoperative
• Fuse(s)
• Circuitry open
• A/C system discharged/low charge
• PCM
• HVAC module
• Evaporator discharge temperature sensor
• A/C clutch field coil
• GO to Pinpoint Test M .
• The air conditioning (A/C) is always on â A/C compressor does not cycle
• Circuitry shorted
• PCM
• A/C clutch field coil
• GO to Pinpoint Test N .
• The air conditioning (A/C) is always on â A/C mode always commanded ON
• Circuitry shorted
• PCM
• HVAC module
• GO to Pinpoint Test O .
• Temperature control is inoperative/does not operate correctly
• HVAC module
• GO to Pinpoint Test P .
• The blower motor is inoperative â EMTC
• Fuse(s)
• Circuitry open
• Blower motor relay
• A/C blower motor
• HVAC module â EMTC
• GO to Pinpoint Test Q .
• The blower motor does not operate correctly â EMTC

• A/C blower motor resistor
• GO to Pinpoint Test R .
• The blower motor is inoperative â DATC
• Fuse(s)
• Circuitry short/open
• HVAC module
• A/C blower motor speed control
• GO to Pinpoint Test S .
• The blower motor does not operate correctly â DATC
• HVAC module
• GO to Pinpoint Test T .
• The temperature set point does not repeat after turning the ignition switch OFF
• Fuse
• HVAC module
• CARRY OUT the HVAC Module Cold Boot Process. If the condition returns, INSTALL a new
HVAC module.
• The temperature display will not switch between Celsius and Fahrenheit
• HVAC module
• INSTALL a new HVAC module. REFER to Section 412-01 .
• The dual temperature control is inoperative/does not operate correctly
• Temperature blend door/actuator broken/binding

• HVAC module â Electronic Automatic Temperature Control (EATC)
• Low A/C refrigerant charge
• NOTE: For the passenger side temperature setting on hybrid vehicles equipped with dual-zone
Electronic Automatic Temperature Control (EATC) and a Front Controls Interface Module (FCIM)
built on or after 04/08/2009 to be functional, a passenger must be seated in the front passenger seat. If
the front passenger seat is not occupied, the HVAC module will control the system based only on the
driver side temperature setting. The HVAC module receives a Medium Speed Controller Area
Network (MS-CAN) signal from the FCIM to indicate if the front passenger seat is occupied.
CHECK that the A/C system pressure is above 290 kPa (42 psi). If the pressure is below 290 kPa (42

psi), REFER to Fluorescent Dye Leak Detection in this section. CHECK the temperature blend
doors/actuators for a binding or broken condition. If no condition is found, INSTALL a new HVAC
module.
• Inaccurate external temperature display
• HVAC module
• Ambient temperature sensor
• REFER to description and operation of the HVAC module external temperature display. If the
external temperature display is not operating as described and no DTC is present, CARRY OUT the
Ambient Temperature Sensor component test in this section. If the sensor tests OK, INSTALL a new
HVAC module. REFER to Section 412-01 . TEST the system for normal operation.
• A/C pressure relief valve discharging
• High system pressure

• A/C pressure relief valve
• CHECK the high side system pressure. If the pressure is below the A/C pressure relief valve open
pressure, REPLACE the A/C pressure relief valve. If the system pressure is above the A/C pressure
relief valve open pressure, REPAIR the system for a restriction.
Symptom Chart â NVH
Symptom Chart â NVH

NOTE: NVH symptoms will be identified using the diagnostic tools that are available. For a list of these
• Noisy A/C compressor clutch
• A/C compressor clutch air gap out of specification
• CHECK and ADJUST the A/C compressor clutch gap if necessary. REFER to Air Conditioning
(A/C) Clutch Air Gap Adjustment in this section. TEST the system for normal operation.
• If the A/C compressor clutch gap is OK, INSTALL an A/C compressor clutch. REFER to Section
412-01 . TEST the system for normal operation.
Pinpoint Tests
Pinpoint Test A: DTC P0532 or P0533
Refer to Wiring Diagrams Cell 23 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Electronic Engine Controls

â 2.3L for schematic and connector information.
Normal Operation
Under normal operation, the A/C pressure transducer receives a ground from the PCM through circuit RE407
(YE/VT). A 5-volt reference voltage is supplied to the A/C pressure transducer from the PCM through circuit
LE424 (YE/GN). The A/C pressure transducer sends voltage to the PCM through circuit VH433 (VT/OG) to
indicate the A/C pressure.
• DTC P0532 (A/C Pressure Refrigerant Sensor A Circuit Low) â The A/C pressure transducer
inputs a voltage to the PCM. If the voltage is below the calibrated level, this DTC sets.
• DTC P0533 (A/C Pressure Refrigerant Sensor A Circuit High) â The A/C pressure transducer
inputs a voltage to the PCM. If the voltage is above the calibrated level, this DTC sets.

• PCM
PINPOINT TEST A: DTC P0532 OR P0533

A1 CHECK THE PCM OUTPUT VOLTAGE
Yes
• Disconnect: A/C Pressure Transducer C1260.
• Ignition ON. No
• Measure the voltage between ground and A/C REPAIR circuit LE424 (YE/GN) for an
pressure transducer C1260-2, circuit LE424 (YE/GN), open. CLEAR the DTCs. REPEAT the
harness side. self-test. TEST the system for normal
operation.
• Is the voltage between 4.7 and 5.1 volts?

A2 CHECK THE PCM SENSOR GROUND

• Measure the voltage between A/C pressure transducer Yes

C1260-1, circuit RE407 (YE/VT), harness side and If diagnosing DTC P0532 , GO to A3 . If
A/C pressure transducer C1260-2, circuit LE424 diagnosing DTC P0533 , GO to A5 .
(YE/GN), harness side.
No
REPAIR circuit RE407 (YE/VT) for an
open. CLEAR the DTCs. REPEAT the
self-test. TEST the system for normal
operation.

A3 CHECK THE A/C PRESSURE TRANSDUCER
HIGH
Yes
• Enter the following diagnostic mode on the scan tool: INSTALL a new A/C pressure
A/C Pressure (ACP_PRESS) PCM PID. transducer. CLEAR the DTCs. REPEAT
• While observing the ACP_PRESS PCM PID, connect the self-test. TEST the system for normal
a fused jumper between A/C pressure transducer operation.
C2160-3, circuit VH433 (VT/OG), harness side and
A/C pressure transducer C1260-2, circuit LE424 No
(YE/GN), harness side. GO to A4 .
• Does the ACP_PRESS PCM PID voltage read

greater than 4 volts?
A4 CHECK CIRCUIT VH433 (VT/OG) FOR A SHORT
TO GROUND
Yes
• Disconnect: PCM C175B.
• Measure the resistance between ground and A/C No
pressure transducer C1260-3, circuit VH433 REPAIR circuit VH433 (VT/OG) for a
(VT/OG), harness side. short to ground. CLEAR the DTCs.
REPEAT the self-test. TEST the system
PINPOINT TEST A: DTC P0532 OR P0533 4837


A5 CHECK THE A/C PRESSURE TRANSDUCER
HIGH
Yes
• Enter the following diagnostic mode on the scan tool: INSTALL a new A/C pressure
A/C Pressure (ACP_PRESS) PCM PID. transducer. CLEAR the DTCs. REPEAT
• While observing the ACP_PRESS PCM PID, connect the self-test. TEST the system for normal
a fused jumper between A/C pressure transducer operation.
C1260-3, circuit VH433 (VT/OG), harness side and
A/C pressure transducer C1260-1, circuit RE407 No
(YE/VT), harness side. GO to A6 .
• Does the ACP_PRESS PCM PID voltage read less

than 4.9 volts?
TO VOLTAGE
Yes
• Ignition OFF. REPAIR circuit VH433 (VT/OG) for a
• Disconnect: PCM C175B. short to voltage. CLEAR the DTCs.
• Ignition ON. REPEAT the self-test. TEST the system
• Measure the voltage between ground and A/C for normal operation.
pressure transducer C1260-3, circuit VH433
(VT/OG), harness side. No
GO to A7 .

TO CIRCUIT LE424 (YE/GN) OR RE407 (YE/VT)
Yes
• NOTE: For DTC P0532 only.
• Measure the resistance between A/C pressure No
transducer C1260-3, circuit VH433 (VT/OG), harness REPAIR circuit VH433 (VT/OG) for a
side and A/C pressure transducer C1260-1, circuit short to circuit LE424 (YE/GN) or
RE407 (YE/VT), harness side. RE407 (YE/VT). CLEAR the DTCs.

• NOTE: For DTC P0533 only.

• Measure the resistance between A/C pressure
transducer C1260-3, circuit VH433 (VT/OG), harness
side and A/C pressure transducer C1260-2, circuit
LE424 (YE/GN), harness side.

A8 CHECK CIRCUIT VH433 (VT/OG) FOR AN OPEN
Yes
• For 2.5L and 3.0L only , measure the resistance GO to A9 .
between A/C pressure transducer C1260-3, circuit
VH433 (VT/OG), harness side and PCM C175B-31, No
circuit VH433 (VT/OG), harness side. REPAIR circuit VH433 (VT/OG)Â for
an open. CLEAR the DTCs. REPEAT the
operation.
• For 3.5L only , measure the resistance between A/C

pressure transducer C1260-3, circuit VH433
(VT/OG), harness side and PCM C175B-63, circuit
VH433 (VT/OG), harness side.

A9 CHECK THE PCM CONNECTION

Yes
• Disconnect all the PCM connectors. INSTALL a new PCM. TEST the system
• Inspect the module connectors for: for normal operation.
♦ corrosion.
♦ pushed-out terminals. No
♦ damaged terminals. The system is operating correctly at this
• Connect and correctly seat all the PCM connectors. time. The concern may have been caused
• Clear the DTCs. by a loose or corroded connector.
• Operate the system and verify the concern is still
present.
Pinpoint Test B: DTC P0645
Refer to Wiring Diagrams Cell 54 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Manual Climate Control
System for schematic and connector information.
Refer to Wiring Diagrams Cell 55 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Automatic Climate Control
Normal Operation
Under normal operation, voltage is provided to the A/C clutch relay coil through circuit CBK03 (GY). When
A/C is requested, and A/C line pressures allow, a ground is provided to the A/C clutch relay coil from the
PCM through circuit CH302 (WH/BN), energizing the A/C clutch relay.
• DTC P0645 (A/C Clutch Relay Control Circuit) â The DTC sets when the PCM grounds the relay
circuit and excessive current draw is detected on the relay circuit. The DTC also sets when the relay
circuit is OFF and no voltage is detected on the relay circuit. The PCM expects to detect voltage
coming through the relay coil to the relay circuit when it is not grounding it.

• PCM
PINPOINT TEST B: DTC P0645

B1 CHECK THE VOLTAGE TO THE A/C CLUTCH
RELAY
Yes
• Ignition OFF. CARRY OUT the A/C clutch relay
• Disconnect: A/C Clutch Relay. component test.
• Ignition ON.
• Measure the voltage between ground and the A/C Refer to Wiring Diagrams Cell 149 (
clutch relay socket, circuit CBK03 (GY). Fusion/MKZ , Fusion Hybrid/MKZ
Hybrid ) for component testing.

If the relay tests OK, GO to B2 .
No
REPAIR circuit CBK03 (GY) for an open.
CLEAR the DTCs. REPEAT the self-test.
B2 CHECK CIRCUIT CH302 (WH/BN) FOR A
SHORT TO VOLTAGE
Yes
• Ignition OFF. REPAIR circuit CH302 (WH/BN) for a
• Disconnect: PCM C175B. short to voltage. CLEAR the DTCs.
• Ignition ON. REPEAT the self-test. TEST the system
• For 2.5L and 3.0L only , measure the voltage for normal operation.
between ground and PCM C175B-12, circuit CH302
(WH/BN), harness side. No
GO to B3 .
• For 3.5L only , measure the voltage between ground

and PCM C175B-64, circuit CH302 (WH/BN),
harness side.

B3 CHECK CIRCUIT CH302 (WH/BN) FOR A
SHORT TO GROUND
Yes
• For 2.5L and 3.0L only , measure the resistance
between ground and PCM C175B-12, circuit CH302 No
(WH/BN), harness side. REPAIR circuit CH302 (WH/BN) for a
short to ground. CLEAR the DTCs.
PINPOINT TEST B: DTC P0645 4841

• For 3.5L only , measure the resistance between

ground and PCM C175B-64, circuit CH302
(WH/BN), harness side.

B4 CHECK CIRCUIT CH302 (WH/BN) FOR AN
OPEN
Yes
• For 2.5L and 3.0L only , measure the resistance GO to B5 .
between A/C clutch relay socket, circuit CH302
(WH/BN) and PCM C175B-12, circuit CH302 No
(WH/BN), harness side. REPAIR circuit CH302 (WH/BN) for an
operation.
• For 3.5L only , measure the resistance between A/C

clutch relay socket, circuit CH302 (WH/BN) and
PCM C175B-64, circuit CH302 (WH/BN), harness
side.

B5 CHECK THE PCM CONNECTION
PINPOINT TEST B: DTC P0645 4842

• Disconnect all the PCM connectors. Yes

• Inspect the module connectors for: INSTALL a new PCM. TEST the system
♦ pushed-out terminals.
♦ damaged terminals. No
• Connect and correctly seat all the PCM connectors. The system is operating correctly at this
• Clear the DTCs. time. The concern may have been caused
present.
Pinpoint Test C: DTCs C1B14:11 and 12
Normal Operation
Under normal operation, a 5-volt reference voltage is supplied to the sensors and actuators from the HVAC
module through circuit LH111 (BN/WH).
• DTC C1B14:11 (Sensor Supply Voltage A: Circuit Short to Ground) â The module senses less
than 0.1 volt on the sensor reference voltage circuit, indicating a short directly to ground.
• DTC C1B14:12 (Sensor Supply Voltage A: Circuit Short to Battery) â The module senses greater
than 4.9 volts on the sensor reference voltage circuit, indicating a short directly to voltage.

• HVAC module
PINPOINT TEST C: DTCs C1B14:11 AND 12

C1 CHECK THE SENSOR RESISTANCE
Yes
• Check for HVAC DTCs. GO to C2 .
• Is DTC C1B14:11 present?
No
GO to C4 .
C2 CHECK CIRCUIT LH111 (BN/WH) FOR A SHORT
TO GROUND
Yes
• Disconnect: HVAC Module â Electronic Manual
Temperature Control (EMTC) C2357a. No
• Disconnect: HVAC Module â Dual Automatic REPAIR circuit LH111 (BN/WH) for
Temperature Control (DATC) C2356a. a short to ground. CLEAR the DTCs.

• Disconnect: HVAC Module â DATC C2356b. REPEAT the self-test. TEST the
• Measure the resistance between ground and HVAC system for normal operation.
module â EMTC C2357a-11 or HVAC module â
DATC C2356a-11, circuit LH111 (BN/WH), harness
side.

C3 CHECK CIRCUITS LH111 (BN/WH) AND RH111
(GY/BU) FOR A SHORT TOGETHER
Yes
• Measure the resistance between HVAC module â GO to C5 .
EMTC C2357a-11 or HVAC module â DATC
C2356a-11, circuit LH111 (BN/WH), harness side and No
HVAC module â EMTC C2357a-10 or HVAC REPAIR circuits LH111 (BN/WH)
module C2356a-10, circuit RH111 (GY/BU), harness and RH111 (GY/BU) for a short
side. together. CLEAR the DTCs. REPEAT
the self-test. TEST the system for
normal operation.
• Is the resistance greater than 200 ohms?

C4 CHECK CIRCUIT LH111 (BN/WH) FOR A SHORT
TO VOLTAGE
Yes
• Ignition OFF. REPAIR circuit LH111 (BN/WH) for
• Disconnect: HVAC Module â EMTC C2357a. a short to voltage. CLEAR the DTCs.
• Disconnect: HVAC Module â DATC C2356a. REPEAT the self-test. TEST the
• Disconnect: HVAC Module â DATC C2356b. system for normal operation.
• Ignition ON.
• Measure the voltage between ground and HVAC module No
â EMTC C2357a-11 or HVAC module â DATC GO to C5 .
C2356a-11, circuit LH111 (BN/WH), harness side.
PINPOINT TEST C: DTCs C1B14:11 AND 12 4844


C5 CHECK THE MODULE CONNECTION
Yes
• Inspect the module connectors for: INSTALL a new HVAC module.
♦ corrosion. REFER to Section 412-01 . TEST the
♦ pushed-out terminals. system for normal operation.
♦ damaged terminals.
• Connect and correctly seat all the HVAC module No
connectors. The system is operating correctly at
• Clear the DTCs. this time. The concern may have been
• Operate the system and verify the concern is still caused by a loose or corroded
present. connector. CLEAR the DTCs.
• Is the concern still present? REPEAT the self-test. TEST the
Pinpoint Test D: DTCs B1A61:11 and 15
Normal Operation
Under normal operation, the in-vehicle air temperature sensor receives a ground from the HVAC module
through circuit RH111 (GY/BU). A 5-volt reference voltage is supplied to the in-vehicle air temperature
sensor from the HVAC module through circuit VH414 (GN/BU).
• DTC B1A61:11 (Cabin Temperature Sensor: Circuit Short to Ground) â The module senses
excessive voltage drop on the sensor reference voltage circuit, indicating a short directly to ground.
• DTC B1A61:15 (Cabin Temperature Sensor: Circuit Short to Battery or Open) â The module
senses no voltage drop on the sensor reference voltage circuit, indicating a short directly to voltage or
an open circuit.

• In-vehicle air temperature sensor
• HVAC module
PINPOINT TEST D: DTCs B1A61:11 AND 15

D1 CHECK THE SENSOR RESISTANCE


• Disconnect: In-Vehicle Temperature Sensor C233. GO to D2 .
• Measure the resistance between the in-vehicle
temperature sensor C233 terminals and compare to No
the table below. INSTALL a new in-vehicle temperature
sensor. CLEAR the DTCs. REPEAT the
operation.
Ambient Temperature Resistance

-40Â°C (-40Â°F) 869,073-1,061,986 ohms
-15Â°C (5Â°F) 196,465-231,213 ohms
0Â°C (32Â°F) 89,982-102,514 ohms
15Â°C (59Â°F) 44,261-49,503 ohms
25Â°C (77Â°F) 28,500-31,500 ohms
35Â°C (95Â°F) 18,563-20,751 ohms
60Â°C (140Â°F) 6,971-8,001 ohms
85Â°C (185Â°F) 2,959-3,474 ohms
• Is the resistance within the specified values for

the temperatures?
D2 CHECK THE SENSOR OUTPUT VOLTAGE
Yes
• Ignition ON. INSTALL a new in-vehicle sensor. CLEAR
• Measure the voltage between in-vehicle the DTCs. REPEAT the self-test. If code
temperature sensor C233-1, circuit VH414 returns, GO to D8 .
(GN/BU), harness side and C233-3, circuit RH111
(GY/BU), harness side. No
For DTC B1A68:15 , GO to D3 .
For DTC B1A68:11 , GO to D6 .

D3 CHECK CIRCUIT VH414 (GN/BU) FOR A
SHORT TO VOLTAGE
PINPOINT TEST D: DTCs B1A61:11 AND 15 4846


• Disconnect: HVAC Module â Dual Automatic REPAIR circuit VH414 (GN/BU) for a short
Temperature Control (DATC) C2356a. to voltage. CLEAR the DTCs. REPEAT the
• Disconnect: HVAC Module â DATC C2356b. self-test. TEST the system for normal
• Ignition ON. operation.
• Measure the voltage between ground and HVAC
module â DATC C2356b-21, circuit VH414 No
(GN/BU), harness side. GO to D4 .

D4 CHECK CIRCUIT VH414 (GN/BU) FOR AN
OPEN
Yes
• Measure the resistance between HVAC module
â DATC C2356b-21, circuit VH414 (GN/BU), No
harness side and in-vehicle temperature sensor REPAIR circuit VH414 (GN/BU) for an
C233-1, circuit VH414 (GN/BU), harness side. open. CLEAR the DTCs. REPEAT the
operation.

D5 CHECK CIRCUIT RH111 (GY/BU) FOR AN
OPEN
Yes
• Measure the resistance between HVAC module GO to D8 .
C2356a-10, circuit RH111 (GY/BU), harness side
and in-vehicle temperature sensor C233-3, circuit No
RH111 (GY/BU), harness side. REPAIR circuit RH111 (GY/BU) for an
operation.


SHORT TO CIRCUIT RH111 (GY/BU)
Yes
• Disconnect: HVAC Module â DATC C2356b.
• Measure the resistance between in-vehicle No
temperature sensor C233-1, circuit VH414 REPAIR circuit VH414 (GN/BU) for a short
(GN/BU), harness side and C233-3, circuit RH111 to circuit RH111 (GY/BU). CLEAR the
(GY/BU), harness side. DTCs. REPEAT the self-test. TEST the

SHORT TO GROUND
Yes
• Measure the resistance between HVAC module GO to D8 .
â DATC C2356b-21, circuit VH414 (GN/BU),
harness side and ground. No
REPAIR circuit VH414 (GN/BU) for a short
to ground. CLEAR the DTCs. REPEAT the
operation.

D8 CHECK THE MODULE CONNECTION
Yes
• Inspect the module connectors for: INSTALL a new HVAC module. REFER to
♦ corrosion. Section 412-01 . TEST the system for normal
♦ pushed-out terminals. operation.
connectors. The system is operating correctly at this
• Clear the DTCs. time. The concern may have been caused by
• Operate the system and verify the concern is still a loose or corroded connector. CLEAR the
present. DTCs. REPEAT the self-test. TEST the
• Is the concern still present? system for normal operation.
Pinpoint Test E: DTCs B1A68:11 and 15

Normal Operation
Under normal operation, the ambient air temperature sensor receives a ground from the HVAC module
through circuit RH111 (GY/BU). A 5-volt reference voltage is supplied to the ambient air temperature sensor
from the HVAC module through circuit VH407 (YE/GN).
• DTC B1A68:11 (Ambient Temperature Sensor: Circuit Short to Ground) â The module senses
• DTC B1A68:15 (Ambient Temperature Sensor: Circuit Short to Battery or Open) â The module
an open circuit.

• HVAC module
PINPOINT TEST E: DTCs B1A68:11 AND 15

E1 CHECK THE SENSOR RESISTANCE
Yes
• Disconnect: Ambient Air Temperature Sensor C132.
• Measure the resistance between the ambient air No
temperature sensor C132 terminals and compare to the INSTALL a new ambient air
table below. temperature sensor. CLEAR the
DTCs. REPEAT the self-test. TEST

-40Â°C (-40Â°F) 832,519-1,017,523 ohms
-15Â°C (5Â°F) 199,325-220,307 ohms
0Â°C (32Â°F) 91,058-100,644 ohms
15Â°C (59Â°F) 44,435-49,113 ohms
25Â°C (77Â°F) 28,500-31,500 ohms
35Â°C (95Â°F) 18,730-20,701 ohms
60Â°C (140Â°F) 7,171-7,925 ohms
85Â°C (185Â°F) 3,110-3,438 ohms

• Is the resistance within the specified values for the

temperatures?
E2 CHECK THE SENSOR OUTPUT VOLTAGE
Yes
• Ignition ON. INSTALL a new ambient air
• Measure the voltage between ambient air temperature temperature sensor. CLEAR the
sensor C132-1, circuit VH407 (YE/GN), harness side DTCs. REPEAT the self-test. If code
and C132-2, circuit RH111 (GY/BU), harness side. returns, GO to E8 .
No
For DTC B1A61:15 , GO to E3 .
For DTC B1A61:11 , GO to E6 .

E3 CHECK CIRCUIT VH407 (YE/GN) FOR A SHORT TO
VOLTAGE
Yes
• Ignition OFF. REPAIR circuit VH407 (YE/GN) for
• Disconnect: HVAC Module â Electronic Manual a short to ground. CLEAR the DTCs.
Temperature Control (EMTC) C2357a. REPEAT the self-test. TEST the
• Disconnect: HVAC Module â Dual Automatic system for normal operation.
Temperature Control (DATC) C2356a.
• Ignition ON. No
• Measure the voltage between HVAC module â DATC GO to E4 .
C2356a-2, circuit VH407 (YE/GN), harness side and
ground.

E4 CHECK CIRCUIT VH407 (YE/GN) FOR AN OPEN
PINPOINT TEST E: DTCs B1A68:11 AND 15 4850


• Measure the resistance between HVAC module â GO to E5 .
DATC C2356a-2, circuit VH407 (YE/GN), harness side
and ambient air temperature sensor C132-1, circuit No
VH407 (YE/GN), harness side. REPAIR circuit VH407 (YE/GN) for
an open. CLEAR the DTCs. REPEAT
normal operation.

E5 CHECK CIRCUIT RH111 (GY/BU) FOR AN OPEN
Yes
• Measure the resistance between HVAC module â GO to E8 .
DATC C2356a-10, circuit RH111 (GY/BU), harness side
and ambient air temperature sensor C132-2, circuit No
RH111 (GY/BU), harness side. REPAIR circuit RH111 (GY/BU) for
normal operation.

CIRCUIT RH111 (GY/BU)
Yes
• Disconnect: HVAC Module â EMTC C2357a.
• Disconnect: HVAC Module â DATC C2356a. No
• Measure the resistance between ambient air temperature REPAIR circuit VH407 (YE/GN) for
sensor C132-1, circuit VH407 (YE/GN), harness side a short to circuit RH111 (GY/BU).
and C132-2, circuit RH111 (GY/BU), harness side. CLEAR the DTCs. REPEAT the
operation.

GROUND
PINPOINT TEST E: DTCs B1A68:11 AND 15 4851

• Measure the resistance between HVAC module â Yes

DATC C2356a-2, circuit VH407 (YE/GN), harness side GO to E8 .
and ground.
No
REPAIR circuit VH407 (YE/GN) for
a short to ground. CLEAR the DTCs.
REPEAT the self-test. TEST the

E8 CHECK THE MODULE CONNECTION
Yes
• Operate the system and verify the concern is still present. caused by a loose or corroded
• Is the concern still present? connector. CLEAR the DTCs.
Pinpoint Test F: DTCs B1A63:11 and 15 or DTCs B1A64:11 and 15
Normal Operation
Under normal operation, the sunload sensor receives a ground from the HVAC module through circuit GD116
(BK/VT). A 5-volt reference voltage is supplied to the sunload sensor from the HVAC module through circuit
VH417 (YE/OG) (RH) and circuit VH416 (VT/GY) (LH).
DTC Description Fault Trigger Conditions

The module senses excessive voltage drop on the sensor reference
• B1A63:11 â Right Solar voltage circuit, indicating a short directly to ground.
Ground
The module senses no voltage drop on the sensor reference voltage
• B1A63:15 â Right Solar circuit, indicating a short directly to voltage or an open circuit.
Sensor: Circuit Short to Battery
or Open
The module senses excessive voltage drop on the sensor reference

• B1A64:11 â Left Solar voltage circuit, indicating a short directly to ground.

Ground
The module senses no voltage drop on the sensor reference voltage
• B1A64:15 â Left Solar circuit, indicating a short directly to voltage or an open circuit.
Sensor: Circuit Short to Battery
or Open

• Sunload sensor
• HVAC module
PINPOINT TEST F: DTCs B1A63:11 AND 15 OR DTCs B1A64:11 AND 15

F1 CHECK THE SUNLOAD SENSOR
REFERENCE VOLTAGE
Yes
• Ignition OFF. INSTALL a new sunload sensor. CLEAR the
• Disconnect: Sunload Sensor C286. DTCs. REPEAT the self-test. If the code
• Ignition ON. returns, GO to F6 .
• Press the AUTO button.
• Measure the voltage between sunload sensor No
C266-4, circuit GD116 (BK/VT), harness side If diagnosing DTC B1A63:15 or DTC
and sunload sensor: B1A64:15 , GO to F2 .
♦ For DTC B1A63 , C286-1, circuit
VH417 (YE/OG), harness side. If diagnosing DTC B1A63:11 or DTC
♦ For DTC B1A64 , C286-3, circuit B1A64:11 , GO to F5 .
VH416 (VT/GY), harness side.

F2 CHECK CIRCUIT VH416 (VT/GY) AND
VH417 (YE/OG) FOR A SHORT TO VOLTAGE
Yes
• Ignition OFF. REPAIR circuit VH416 (VT/GY) or VH417
• Disconnect: HVAC Module â Dual (YE/OG) for a short to voltage. CLEAR the
Automatic Temperature Control (DATC) DTCs. REPEAT the self-test. TEST the
C2356a. system for normal operation.
• Ignition ON. No
• Measure the voltage between ground and GO to F3 .
PINPOINT TEST F: DTCs B1A63:11 AND 15 OR DTCs B1A64:11 AND 15 4853

sunload sensor:
♦ For DTC B1A64:11 , C286-3, circuit
VH416 (VT/GY), harness side.
♦ For DTC B1A63:11 , C286-1, circuit
VH417 (YE/OG), harness side.

F3 CHECK CIRCUIT GD116 (BK/VT) FOR AN
OPEN
Yes
• Measure the resistance between ground and
sunload sensor C286-4, circuit GD116 (BK/VT), No
harness side. REPAIR circuit GD116 (BK/VT) for an open.

F4 CHECK CIRCUITS VH417 (YE/OG) AND
VH416 (VT/GY) FOR AN OPEN
Yes
• Measure the resistance between HVAC module GO to F6 .
â DATC C2356b-6, circuit VH416 (VT/GY),
harness side and sunload sensor C286-3, circuit No
VH416 (VT/GY), harness side. REPAIR circuit VH416 (VT/GY) or circuit
VH417 (YE/OG) for an open. CLEAR the
DTCs. REPEAT the self-test. TEST the

â DATC C2356b-3, circuit VH417 (YE/OG),
harness side and sunload sensor C286-1, circuit


F5 CHECK CIRCUIT VH417 (YE/OG) OR
CIRCUIT VH416 (VT/GY) FOR A SHORT TO
GROUND
Yes
• Disconnect: HVAC Module â DATC C2356a.
• Disconnect: HVAC Module â DATC C2356b. No
• Measure the resistance between ground and REPAIR circuits VH417 (YE/OG) or VH416
sunload sensor: (VT/GY) for a short to circuit RH111
♦ For DTC B1A64:11 , C286-3, circuit (GY/BU). CLEAR the DTCs. REPEAT the
VH416 (VT/GY), harness side. self-test. TEST the system for normal
♦ For DTC B1A63:11 , C286-1, circuit operation.

F6 CHECK THE MODULE CONNECTION
Yes
connectors. The system is operating correctly at this time.
• Clear the DTCs. The concern may have been caused by a loose
• Operate the system and verify the concern is still or corroded connector. CLEAR the DTCs.
present. REPEAT the self-test. TEST the system for
• Is the concern still present? normal operation.
Pinpoint Test G: DTCs B1B71:11 and 15

Normal Operation
Under normal operation, the evaporator discharge air temperature sensor receives a ground from the HVAC
module through circuit RH111 (GY/BU). A 5-volt reference voltage is supplied to the evaporator discharge
air temperature sensor from the HVAC module through circuit VH406 (VT/BN).
• DTC B1B71:11 (Evaporator Temperature Sensor: Circuit Short to Ground) â The module senses
• DTC B1B71:15 (Evaporator Temperature Sensor: Circuit Short to Battery or Open) â The module
an open circuit.

• Evaporator discharge air temperature sensor
• HVAC module
PINPOINT TEST G: DTCs B1B71:11 AND 15

G1 CHECK THE SENSOR RESISTANCE
Yes
• Ignition OFF. For DTC B1B71:11 , GO to G2
• Disconnect: HVAC Module â Electronic Manual .
Temperature Control (EMTC) C2357a.
• Disconnect: HVAC Module â Dual Automatic Temperature For DTC B1B71:15 , GO to G3
Control (DATC) C2356a. .
• Measure the resistance between HVAC module â EMTC
C2357a-6 or HVAC module â DATC C2356a-6, circuit No
VH406 (VT/BN), harness side and HVAC module â EMTC For DTC B1B71:11 , GO to G4
C2357a-10 or HVAC module â DATC C2356a-10, circuit .
RH111 (GY/BU), harness side .
For DTC B1B71:15 , GO to G5
.
• Compare the measurement to the chart and table of the

Evaporator Discharge Air Temperature Sensor component test
in this section.
temperatures?
G2 CHECK CIRCUIT VH406 (VT/BN) FOR A SHORT TO
GROUND

• Measure the resistance between HVAC module â EMTC Yes

C2357a-6 or HVAC module â DATC C2356a-6, circuit GO to G7 .
VH406 (VT/BN), harness side and ground.
No
REPAIR circuit VH406
(VT/BN) for a short to ground.
CLEAR the DTCs. REPEAT the
self-test. TEST the system for
normal operation.

VOLTAGE
Yes
• Ignition ON. REPAIR circuit VH406
• Measure the voltage between ground and HVAC module â (VT/BN) for a short to voltage.
EMTC C2357a-6 or HVAC module â DATC C2356a-6, CLEAR the DTCs. REPEAT the
circuit VH406 (VT/BN), harness side and ground. self-test. TEST the system for
normal operation.
No
GO to G7 .

Yes
NOTE: Instrument panel removal is required to disconnect the INSTALL a new evaporator
sensor. Before carrying out this test step, visually inspect the discharge air temperature sensor.
wiring between the HVAC module and sensor for shorts. If no CLEAR the DTCs. REPEAT the
damage is visually evident, proceed with the test. self-test. TEST the system for
normal operation.
• Ignition OFF.
• Disconnect: Evaporator Discharge Air Temperature Sensor No
C2295. REPAIR circuit VH406
• Measure the resistance between HVAC module â EMTC (VT/BN) for a short to circuit
C2357a-6 or HVAC module â DATC C2356a-6, circuit RH111 (GY/BU). CLEAR the
VH406 (VT/BN), harness side and HVAC module â EMTC DTCs. REPEAT the self-test.
C2357a-10 or HVAC module â DATC C2356a-10, circuit TEST the system for normal
RH111 (GY/BU), harness side. operation.
PINPOINT TEST G: DTCs B1B71:11 AND 15 4857


G5 CHECK CIRCUITS VH406 (VT/BN) FOR AN OPEN
Yes
NOTE: Instrument panel removal is required to disconnect the GO to G6 .
sensor. Before carrying out this test step, visually inspect the
wiring between the HVAC module and sensor for opens. If no No
damage is visually evident, proceed with the test. REPAIR circuit VH406
(VT/BN) for an open. CLEAR
• Ignition OFF. the DTCs. REPEAT the
• Disconnect: Evaporator Discharge Air Temperature Sensor self-test. TEST the system for
C2295. normal operation.
• Measure the resistance between HVAC module â EMTC
C2357a-6 or HVAC module â DATC C2356a-6, circuit
VH406 (VT/BN), harness side and inline ( EMTC ) C211-13
or ( DATC ) inline C213-13, circuit VH406 (VT/BN),
instrument panel harness side.
• Measure the resistance between inline ( EMTC ) C211-13 or (

DATC ) inline C213-13, circuit VH406 (VT/BN), HVAC case
harness side and evaporator discharge air temperature sensor
C2295-1, circuit VH406 (VT/BN), harness side.

G6 CHECK CIRCUITS RH111 (GY/BU) FOR AN OPEN

• Measure the resistance between HVAC module â EMTC Yes

C2357a-10 or HVAC module â DATC C2356a-10, circuit INSTALL a new evaporator
RH111 (GY/BU), harness side and inline ( EMTC ) C211-15 discharge air temperature sensor.
or ( DATC ) inline C213-15, circuit RH111 (GY/BU), CLEAR the DTCs. REPEAT the
instrument panel harness side. self-test. TEST the system for
normal operation.
No
REPAIR circuit RH111
(GY/BU) for an open. CLEAR
the DTCs. REPEAT the
normal operation.
• Measure the resistance between inline ( EMTC ) C211-15 or (

DATC ) inline C213-15, circuit RH111 (GY/BU), HVAC case
harness side and evaporator discharge air temperature sensor
C2295-2, circuit RH111 (GY/BU), harness side.

G7 CHECK THE MODULE CONNECTION
Yes
• Inspect the module connectors for: INSTALL a new HVAC
♦ corrosion. module. REFER to Section
♦ pushed-out terminals. 412-01 . TEST the system for
♦ damaged terminals. normal operation.
• Connect and correctly seat all the HVAC module connectors.
• Clear the DTCs. No
• Operate the system and verify the concern is still present. The system is operating
• Is the concern still present? correctly at this time. The
concern may have been caused
by a loose or corroded
connector. CLEAR the DTCs.
Pinpoint Test H: DTCs U3003:16 and 17

NOTE: DTC U3003 can be set if the vehicle has been recently jump started, the battery has been recently
charged or the battery has been discharged. The battery may become discharged due to excessive load(s) on
the charging system from aftermarket accessories or if the battery has been left unattended with the
accessories on.
NOTE: Carry out a thorough inspection and verification before proceeding with the pinpoint test. Refer to
Inspection and Verification in this section.
Normal Operation
Under normal operation, the HVAC module receives a ground through circuit GD116 (BK/VT). The HVAC
module is supplied constant battery voltage through circuit SBP15 (WH/RD).
• DTC U3003:16 (Control Module Input Power "A": Circuit Voltage Below Threshold) â The
module senses when battery voltage is greater than 16 volts.
• DTC U3003:17 (Control Module Input Power "A": Circuit Voltage Above Threshold) â The
module senses when battery voltage is less than 9 volts.

• HVAC module
PINPOINT TEST H: DTCs U3003:16 AND 17

H1 RETRIEVE ALL CMDTCs IN ALL MODULES
Yes
• Ignition ON. REFER to Section 414-00 for diagnosis of
• Enter the following diagnostic mode on the scan the battery and charging system.
tool: Self Test â All CMDTCs .
• Is DTC B1317, B1318 or B1676 present in one or No
more modules and DTC P0563, P0620, P0625, GO to H2 .
P0626 or P065B present in the PCM?
H2 CHECK BATTERY CONDITION
Yes
• Ignition OFF. If the battery passed the condition test but
• Refer to Section 414-01 and carry out the Battery required a recharge, REFER to Section
â Condition Test 414-00 to diagnose the charging system.
• Does the battery pass the condition test? CLEAR all Continuous Memory
Diagnostic Trouble Codes (CMDTCs).
If the battery passed the condition test and

did not require a recharge, GO to H3 .
No
INSTALL a new battery. CLEAR all
CMDTCs . TEST the system for normal
operation.
H3 CHECK THE CHARGING SYSTEM VOLTAGE

NOTE: Do not allow the engine rpm to increase Yes

above 2,000 rpm while performing this step or the For DTC U3003:17 , GO to H4 .
generator may self excite and result in default
charging system output voltage. If engine rpm has For DTC U3003:16 , INSTALL a new
gone above 2,000 rpm, shut the vehicle OFF and HVAC module. REFER to Section 412-01
restart the engine before performing this step. . CLEAR all CMDTCs . REPEAT the
self-test.
• Measure the voltage of the battery: No
♦ For DTC U3003:17 , turn off all accessories REFER to Section 414-00 to diagnose the
and run the engine at 1,500 rpm for a charging system. CLEAR all CMDTCs .
minimum of 2 minutes. TEST the system for normal operation.
♦ For DTC U3003:16 , turn on headlights and
HVAC fan on high and run engine at 1,500
rpm for a minimum of 2 minutes.
• Is the battery voltage between 13-15.2 volts?

H4 CHECK CIRCUITS SBP15 (WH/RD) FOR AN
OPEN
Yes
• Ignition OFF. GO to H5 .
• Disconnect: HVAC Module â Dual Automatic VERIFY Smart Junction Box (SJB) fuse
Temperature Control (DATC) C2356a. 15 (10A) is OK. If OK, REPAIR circuit
• Ignition ON. SBP15 (WH/RD) for an open. CLEAR all
• With the engine running, measure the voltage CMDTCs . REPEAT the self-test. If not
between HVAC module â EMTC C2357a-13 or OK, REFER to the Wiring Diagrams
HVAC module â DATC C2356a-13, circuit manual to identify the possible causes of
SBP15 (WH/RD), harness side and ground. the circuit short.

H5 CHECK CIRCUIT GD133 (BK) FOR AN OPEN
PINPOINT TEST H: DTCs U3003:16 AND 17 4861


• Measure the resistance between HVAC module â GO to H6 .
C2356a-23, circuit GD116 (BK/VT), harness side No
and ground. REPAIR circuit GD116 (BK/VT) for an
♦ Repeat this measurement while wiggling the open. TEST the system for normal
harness. operation.

H6 CHECK THE MODULE CONNECTION
Yes
• Inspect the module connectors for: INSTALL a new HVAC module. REFER
♦ corrosion. to Section 412-01 . TEST the system for
♦ pushed-out terminals. normal operation.
• Operate the system and verify the concern is still by a loose or corroded connector. CLEAR
present. the DTCs. REPEAT the self-test. TEST
• Is the concern still present? the system for normal operation.
Pinpoint Test I: Unable to Duplicate the Customer Concern and No DTCs Present

• Incorrect functioning of the HVAC system
PINPOINT TEST I: UNABLE TO DUPLICATE CUSTOMER CONCERN AND NO DTCs PRESENT
NOTE: Diagnose any HVAC module DTCs before carrying out the following pinpoint test.
Refer to PCM DTC Chart.

I1 CHECK THE BLOWER MOTOR
OPERATION
Yes
• Ignition ON. GO to I2 .
• Select PANEL mode.
• Observe blower motor operation and select No
each blower motor speed. For Electronic Manual Temperature Control
(EMTC) systems, if the blower motor does not

4862
• Does the blower motor operate in all operate in any setting, GO to Pinpoint Test Q .
selections and change speed in each?
For Dual Automatic Temperature Control (DATC)
systems, if the blower motor does not operate in
any setting, GO to Pinpoint Test S .
For EMTC systems if the blower motor does not

properly change speeds or shut OFF, GO to
Pinpoint Test R .
For DATC systems if the blower motor does not

properly change speeds or shut OFF, GO to
Pinpoint Test T .
I2 CHECK AIRFLOW OPERATION
Yes
• Select the highest blower motor setting. GO to I3 .
• NOTE: Refer to Description and Operation
in this section for proper airflow No
descriptions. GO to Pinpoint Test K .
• While observing the airflow, select each of
the airflow positions (PANEL,
PANEL/FLOOR, FLOOR,
FLOOR/DEFROST, DEFROST).
• Is the airflow directed to the proper
outlets?
I3 VERIFY TEMPERATURE CONTROL
OPERATION
Yes
• Start the vehicle and allow it to reach normal GO to I4 .
operating temperature.
• With the A/C OFF, select PANEL mode. No
• Change the temperature setting from the If the temperature does not get very warm, GO to
coldest to the warmest and back to the Pinpoint Test L .
coldest.
• Does the temperature change between If the temperature does not change at all, GO to
very warm to cool? Pinpoint Test P .
I4 VERIFY THE A/C CLUTCH DOES NOT
ENGAGE WITH A/C OFF
Yes
• With the A/C OFF, select PANEL mode. GO to I5 .
• Select the coldest temperature setting.
• Is the outlet temperature close to ambient No
temperature? If the temperature is warmer than ambient
temperature, GO to Pinpoint Test P and diagnose
for inoperative blend door.
If the outlet temperature is significantly colder

than ambient temperature and the A/C compressor
clutch cycles normally, GO to Pinpoint Test O .
If the outlet temperature is significantly colder

than ambient temperature and the A/C compressor
clutch does not cycle, GO to Pinpoint Test N .

4863
I5 VERIFY A/C CLUTCH ENGAGEMENT IN

THE A/C MODE
Yes
• Make sure the ambient air temperature is GO to I6 .
above 2Â°C (35Â°F).
• Select PANEL mode. No
• Press the A/C button (indicator ON). GO to Pinpoint Test M .
• Does the A/C clutch engage when the
PANEL and A/C button (indicator ON) is
pressed?
I6 CHECK THE RECIRC OPERATION
Yes
• Press the RECIRC button (indicator OFF). The system is operating normally.
• Select the highest blower motor setting. No
• Observe airflow noise. GO to Pinpoint Test J .
• Press the RECIRC button (indicator ON).
• Does the airflow noise increase when the
RECIRC mode is selected (indicator ON)?
Pinpoint Test J: The Air Inlet Door is Inoperative
Normal Operation
Under normal operation, to rotate the air inlet mode door actuator, the HVAC module supplies voltage or
ground to the air inlet mode door actuator through the circuit CH207 (BU/GY), and supplies ground or
voltage through circuit CH208 (GN/OG) depending on desired rotation direction.
• DTC B1083:11 (Recirculation Damper Motor: Circuit Short to Ground) â The module senses
excessive voltage drop on the actuator motor circuit, indicating a short directly to ground.
• DTC B1083:12 (Recirculation Damper Motor: Circuit Short to Battery) â The module senses no
voltage drop on the actuator motor circuit, indicating a short directly to voltage.
• DTC B1083:13 (Recirculation Damper Motor: Circuit Open) â The module senses no voltage drop
on the actuator motor circuit, indicating an open.

• HVAC module
• Stuck or bound linkage or door
PINPOINT TEST J: THE AIR INLET DOOR IS INOPERATIVE

J1 CHECK THE HVAC MODULE FOR DTCs

Yes
• Ignition OFF. For DTC B1083:11 , GO to J2 .
Temperature Control (EMTC) C2357a. For DTC B1083:12 , GO to J3 .
• Disconnect: HVAC Module â Dual Automatic
Temperature Control (DATC) C2356a. For DTC B1083:13 , GO to J4 .
• Ignition ON. No
• Check the HVAC module for DTCs. INSPECT for broken/binding linkage or
• Are any DTCs present? door. REPAIR as necessary. If no
condition is found, GO to J6 .
J2 CHECK CIRCUITS CH207 (BU/GY) AND CH208
(GN/OG) FOR A SHORT TO GROUND
Yes
• Ignition OFF. GO to J5 .
• Disconnect: HVAC Module â DATC C2356b. REPAIR circuit CH207 (BU/GY) or
• Measure the resistance between ground and: circuit CH208 (GN/OG) for a short to
♦ HVAC module â EMTC C2357a-16 or ground. CLEAR the DTCs. REPEAT
HVAC module â DATC C2356a-16, circuit the self-test. TEST the system for
CH208 (GN/OG), harness side. normal operation.
♦ HVAC module â EMTC C2357a-15 or
HVAC module â DATC C2356a-15, circuit
CH207 (BU/GY), harness side.

J3 CHECK CIRCUITS CH207 (BU/GY) AND CH208
(GN/OG) FOR A SHORT TO VOLTAGE
Yes
• Ignition OFF. REPAIR circuit CH207 (BU/GY) or
• Disconnect: HVAC Module â EMTC C2357a. circuit CH208 (GN/OG) for a short to
• Disconnect: HVAC Module â DATC C2356a. voltage. CLEAR the DTCs. REPEAT
• Disconnect: HVAC Module â DATC C2356b. the self-test. TEST the system for
• Ignition ON. normal operation.
• Measure the voltage between ground and:
♦ HVAC module â EMTC C2357a-16 or No
HVAC module â DATC C2356a-16, circuit GO to J5 .
CH208 (GN/OG), harness side.
CH207 (BU/GY), harness side.
PINPOINT TEST J: THE AIR INLET DOOR IS INOPERATIVE 4865


J4 CHECK THE ACTUATOR MOTOR DRIVE
CIRCUITS FOR AN OPEN
Yes
• Disconnect: HVAC Module â DATC C2356b. REPAIR the circuit(s) for an open.
• Disconnect: Air Inlet Mode Door Actuator C289. TEST the system for normal operation.
• Measure the resistance between HVAC module â
C2356a-15, circuit CH207 (BU/GY), harness side and
air inlet mode door actuator C289-6, circuit CH207
(BU/GY), harness side.

C2356a-16, circuit CH208 (GN/OG), harness side and
air inlet mode door actuator C289-5, circuit CH208
(GN/OG), harness side.
• Are the resistances less than 5 ohms?

J5 CHECK CIRCUIT CH207 (BU/GY) FOR A SHORT
TO CIRCUIT CH208 (GN/OG)


• Measure the resistance between HVAC module â GO to J6 .
C2356a-15, circuit CH207 (BU/GY), harness side and No
HVAC module â EMTC C2357a-16 or HVAC REPAIR circuit CH208 (GN/OG) for a
module â DATC C2356a-16, circuit CH208 short to circuit CH207 (BU/GY).
(GN/OG), harness side. CLEAR the DTCs. REPEAT the
operation.

J6 CHECK THE ACTUATOR CONNECTION
Yes
• Disconnect the actuator connector. CARRY OUT the Air Inlet Mode Door
• Check for: Actuator component test in this section.
♦ corrosion. If the actuator tests OK, GO to J7 .
• Connect and correctly seat the actuator connector. The system is operating correctly at this
• Clear the DTCs. time. The concern may have been
• Operate the system and verify the concern is still caused by a loose or corroded connector.
present. CLEAR the DTCs. TEST the system for
J7 CHECK THE MODULE CONNECTION
Yes
• Clear the DTCs. time. The concern may have been
present. CLEAR the DTCs. REPEAT the
• Is the concern still present? self-test. TEST the system for normal
operation.
Pinpoint Test K: Incorrect/Erratic Direction of Airflow From Outlets

Normal Operation
Under normal operation, to rotate the mode door actuator, the HVAC module supplies voltage or ground to
the DEFROST/PANEL/FLOOR mode door actuator motor through circuit CH228 (YE/GY), and supplies
ground or voltage through circuit CH229 (WH/BU) depending on desired rotation direction.
The mode door actuator feedback resistor is supplied a ground from the HVAC module through circuit RH111
(GY/BU) and a 5-volt reference voltage on circuit LH111 (BN/WH). The HVAC module reads the voltage on
the mode door actuator feedback circuit VH436 (YE/VT) to determine the mode door actuator position by the
position of the actuator feedback resistor wiper arm.

The module senses no changes in the feedback circuit when
• B1086:07 â Air Distribution motor movement is commanded and no motor DTCs are
Damper Motor: Mechanical Failures present.
The module senses excessive voltage drop on the actuator
• B1086:11 â Air Distribution motor circuit, indicating a short directly to ground.
Damper Motor: Circuit Short to
Ground
The module senses no voltage drop on the actuator motor
• B1086:12 â Air Distribution circuit, indicating a short directly to voltage.
Damper Motor: Circuit Short to
Battery
The module senses no voltage drop on the actuator motor
• B1086:13 â Air Distribution circuit, indicating an open.
Damper Motor: Circuit Open
The module senses excessive voltage drop on the actuator
• B11E7:11 â Air Distribution feedback circuit, indicating a short directly to ground.
Damper Position Sensor: Circuit Short
to Ground
The module senses no voltage drop on the actuator feedback
• B11E7:15 â Air Distribution circuit, indicating an open circuit or a short directly to
Damper Position Sensor: Circuit Short voltage.
to Battery or Open

• HVAC module
PINPOINT TEST K: INCORRECT/ERRATIC DIRECTION OF AIRFLOW FROM OUTLETS

K1 CHECK THE HVAC MODULE FOR DTCs
Yes

• Ignition ON. For DTC B1086:07 , INSPECT for

• Check the HVAC module for DTCs. binding/damaged linkage or door.
• Are any DTCs present? REPAIR as necessary. If no condition is
found, INSTALL a new
defrost/panel/floor door actuator.
operation.
For DTC B1086:11 , GO to K2 .
For DTC B11E7:11 , GO to K6 .
For DTC B11E7:15 , GO to K8 .
No
INSPECT for broken linkage or door.
REPAIR as necessary. If no condition is
found, GO to K13 .
K2 CHECK THE ACTUATOR MOTOR DRIVE
CIRCUITS FOR A SHORT TO GROUND
Yes
• Ignition OFF. GO to K5 .
• Disconnect: HVAC Module â Dual Automatic REPAIR the circuit CH228 (YE/GY) or
Temperature Control (DATC) C2356a. CH229 (WH/BU) for a short to ground.
• Disconnect: HVAC Module â DATC C2356b. TEST the system for normal operation.
• Disconnect: Defrost/Panel/Floor Mode Door Actuator
C2278.
• Measure the resistance between ground and:
CH229 (WH/BU), harness side.
CH228 (YE/GY), harness side.

CIRCUITS FOR A SHORT TO VOLTAGE
PINPOINT TEST K: INCORRECT/ERRATIC DIRECTION OF AIRFLOW FROM OUTLETS 4869


• Disconnect: HVAC Module â EMTC C2357a. REPAIR the circuit CH228 (YE/GY) or
• Disconnect: HVAC Module â DATC C2356a. CH229 (WH/BU) for a short to voltage.
• Disconnect: HVAC Module â DATC C2356b. TEST the system for normal operation.
C2278. No
• Ignition ON. GO to K5 .
CH229 (WH/BU), harness side.
CH228 (YE/GY), harness side.

Yes
• Disconnect: HVAC Module â DATC C2356b. REPAIR the circuit CH228 (YE/GY) or
• Disconnect: Defrost/Panel/Floor Mode Door Actuator CH229 (WH/BU) for an open. TEST
C2278. the system for normal operation.
• Measure the resistance between defrost/panel/floor
door actuator C2278-5, circuit CH228 (YE/GY),
harness side and HVAC module â EMTC
C2357a-20 or HVAC module â DATC C2356a-20,
circuit CH228 (YE/GY), harness side.
• Measure the resistance between defrost/panel/floor

door actuator C2278-6, circuit CH229 (WH/BU),
C2357a-19 or HVAC module â DATC C2356a-19,
circuit CH229 (WH/BU), harness side.


CIRCUITS FOR A SHORT TOGETHER
Yes
EMTC C2357a-20 or HVAC module â DATC No
C2356a-20, circuit CH228 (YE/GY), harness side and REPAIR circuits CH228 (YE/GY) and
HVAC module â EMTC C2357a-19 or HVAC CH229 (WH/BU) for a short together.
module â DATC C2356a-19, circuit CH229 TEST the system for normal operation.
(WH/BU), harness side.

K6 CHECK CIRCUIT VH436 (YE/VT) FOR A SHORT
TO GROUND
Yes
• Disconnect: HVAC Module â DATC C2356b. REPAIR circuit VH436 (YE/VT) for a
• Measure the resistance between ground and HVAC short to ground. TEST the system for
module â EMTC C2357a-8 or HVAC module â normal operation.
DATC C2356a-8, circuit VH436 (YE/VT), harness
side.

K7 CHECK CIRCUIT RH111 (GY/BU) FOR A SHORT
TO CIRCUIT VH436 (YE/VT)

• Disconnect: Defrost/Panel/Floor Mode Door Actuator Yes

C2278. GO to K13 .
EMTC C2357a-10 or HVAC module â DATC No
C2356a-10, circuit RH111 (GY/BU), harness side and REPAIR circuits RH111 (GY/BU) and
HVAC module â EMTC C2357a-8 or HVAC VH436 (YE/VT) for a short together.
module â DATC C2356a-8, circuit VH436 TEST the system for normal operation.
(YE/VT), harness side.

K8 CHECK CIRCUIT VH436 (YE/VT) FOR A SHORT
TO VOLTAGE
Yes
• Ignition OFF. REPAIR circuit VH436 (YE/VT) for a
• Disconnect: HVAC Module â EMTC C2357a. short to voltage. TEST the system for
• Disconnect: HVAC Module â DATC C2356a. normal operation.
• Ignition ON. No
• Measure the voltage between ground and HVAC GO to K9 .
module â EMTC C2357a-8 or HVAC module â
DATC C2356a-8, circuit VH436 (YE/VT), harness
side.

K9 CHECK CIRCUIT LH111 (BN/WH) FOR A SHORT
TO CIRCUIT VH436 (YE/VT)
Yes
C2278. No
• Measure the resistance between HVAC module â REPAIR circuits LH111 (BN/WH) and
EMTC C2357a-11 or HVAC module â DATC VH436 (YE/VT) for a short together.
C2356a-11, circuit LH111 (BN/WH), harness side and TEST the system for normal operation.
HVAC module â EMTC C2357a-8 or HVAC
module â DATC C2356a-8, circuit VH436


K10 CHECK CIRCUIT VH436 (YE/VT) FOR AN OPEN
Yes
• Measure the resistance between HVAC module â GO to K11 .
C2356a-8, circuit VH436 (YE/VT), harness side and No
defrost/panel/floor mode door actuator C2278-9, circuit REPAIR circuit VH436 (YE/VT) for an
VH436 (YE/VT), harness side. open. TEST the system for normal
operation.

K11 CHECK THE ACTUATOR RETURN CIRCUIT
RH111 (GY/BU) FOR AN OPEN
Yes
C2356a-10, circuit RH111 (GY/BU), harness side and No
defrost/panel/floor mode door actuator C2278-8, circuit REPAIR circuit RH111 (GY/BU) for an
RH111 (GY/BU), harness side. open. TEST the system for normal
operation.

K12 CHECK CIRCUIT LH111 (BN/WH) FOR AN OPEN
Yes
C2356a-11, circuit LH111 (BN/WH), harness side and No
defrost/panel/floor mode door actuator C2278-10, REPAIR circuit LH111 (BN/WH) for
circuit LH111 (BN/WH), harness side. an open. TEST the system for normal

operation.

K13 CHECK THE ACTUATOR CONNECTION
Yes
• Inspect the connector for: CARRY OUT the Defrost/Panel/Floor
♦ corrosion. Mode Door Actuator component test in
♦ pushed-out terminals. this section. If the actuator tests OK,
♦ damaged terminals. GO to K14 .
• Connect and correctly seat the actuator connector.
• Operate the system and verify the concern is still The system is operating correctly at this
present. time. The concern may have been
• Is the concern still present? caused by a loose or corroded
connector. CLEAR the DTCs. TEST the
K14 MODULE ACTUATOR POSITION CALIBRATION
Yes
NOTE: The purpose of the module actuator position INSTALL a new HVAC module.
calibration is to allow the HVAC module to reinitialize REFER to Section 412-01 . TEST the
and calibrate the actuator stop points. To carry out the system for normal operation.
calibration, follow the steps below.
No
• Ignition OFF. The system is now operating correctly
• Inspect the module connectors for: at this time. The concern may have been
♦ corrosion. caused by a foreign object in the HVAC
♦ pushed-out terminals. case or temporary binding that restricted
♦ damaged terminals. actuator door travel. CHECK any
• Connect and correctly seat all the HVAC module actuator external linkage. If condition
connectors. recurs, INSPECT actuator linkage and
• Ignition ON. door for binding and CHECK HVAC
• Clear the DTCs. case for foreign objects.
• Select any position except OFF.
• NOTE: The HVAC module will now initialize and
calibrate the actuators. Calibration of the actuators will
take approximately 30 seconds.
present.
Pinpoint Test L: Insufficient, Erratic or No Heat
Normal Operation
Under normal operation, warm coolant flows from the engine through the heater core and back to the engine.

• Plugged heater core
• Coolant level
• Temperature blend door
PINPOINT TEST L: INSUFFICIENT, ERRATIC OR NO HEAT

L1 CHECK FOR CORRECT ENGINE COOLANT
LEVEL
Yes
• Ignition OFF. GO to L3 .
• Check the engine coolant level when hot and cold.
• Is the engine coolant at the correct level (hot/cold) as No
indicated on the engine coolant recovery reservoir? GO to L2 .
L2 CHECK THE ENGINE COOLING SYSTEM FOR
LEAKS
Yes
• Pressure test the cooling system for leaks. Refer to REPAIR the engine coolant leak.
Section 303-03A or Section 303-03B . TEST the system for normal
• Does the engine cooling system leak? operation.
No
GO to L3 .
L3 CHECK FOR COOLANT FLOW TO THE HEATER
CORE
Yes
• Run the engine until it reaches normal operation GO to L4 .
temperature. Select the FLOOR position on the control
assembly. Set the temperature control to full warm and No
the blower to the lowest setting. REFER to Section 303-03A or Section
• Using a suitable temperature measuring device, check 303-03B to check cooling system
the heater core inlet hose to see if it is hot. function.
• Is the heater core inlet hose hot?

L4 CHECK FOR A PLUGGED OR RESTRICTED
HEATER CORE
PINPOINT TEST L: INSUFFICIENT, ERRATIC OR NO HEAT 4875

• Using a suitable temperature measuring device, measure Yes

the heater core outlet hose temperature. For EMTC systems, GO to Pinpoint
Test P and diagnose for a temperature
blend door actuator. For DATC
systems, GO to Pinpoint Test Q and
diagnose for a temperature blend door
actuator.
No
INSTALL a new heater core. TEST
• Is the heater core outlet hose temperature similar to
the inlet hose temperature (within approximately
6-17Â°C [10-30Â°F])?
Pinpoint Test M: The Air Conditioning (A/C) is Inoperative
Normal Operation
Under normal operation, for Fusion equipped with navigation and all MKZ vehicles, when A/C button is
pressed, a message is sent from the Front Controls Interface Module (FCIM) over the Medium Speed
Controller Area Network (MS-CAN) bus to the HVAC module. The HVAC module then sends an A/C
request message over the MS-CAN bus to the Instrument Cluster (IC), then from the IC through the High
Speed Controller Area Network (HS-CAN) bus to the PCM.
For all vehicles equipped with navigation , when MAX A/C is selected on the touch screen, the Audio
Control Module (ACM) sends a message over the MS-CAN bus to the HVAC module that MAX A/C has
been selected.
For Fusion not equipped with navigation , when A/C is requested, a message is sent over the MS-CAN bus
to the IC , then from the IC through the HS-CAN bus to the PCM.
Ignition voltage is provided to the A/C clutch relay switch through circuit SBB25 (RD). When the PCM
energizes the relay, ignition voltage is supplied to the A/C clutch through circuit CH401 (VT/WH). Ground is
supplied for the A/C clutch through circuit GD121 (BK/YE).
When an A/C request is received by the PCM, the A/C compressor clutch will only be engaged through the
A/C clutch relay if all of the following conditions are met:
• The PCM does not detect excessively high or low refrigerant pressure from the A/C pressure
transducer.
• The PCM does not detect excessively high engine coolant temperature.
• The PCM does not detect an ambient air temperature below -1Â°C (30Â°F).
• The PCM has not detected a Wide Open Throttle (WOT) condition.
• The HVAC module does not detect an evaporator discharge air temperature below 2Â°C (36Â°F).

• Fuse(s)
• PCM
• HVAC module
• FCIM
• ACM
• A/C evaporator discharge temperature sensor
• A/C compressor clutch field coil
• A/C control relay
• A/C clutch air gap
PINPOINT TEST M: THE AIR CONDITIONING (A/C) IS INOPERATIVE
NOTE: Before carrying out the following test, diagnose any HVAC, PCM or Instrument Cluster (IC) DTCs.
NOTE: Before carrying out the following test, check that the A/C system pressure is above 290 kPa (42 psi).
If the pressure is below 290 kPa (42 psi), refer to Fluorescent Dye Leak Detection in this section.

M1 CHECK THE A/C PRESSURE SENSOR (ACP_PRESS) PCM
PID
Yes
• Ignition ON. GO to M2 .
• Enter the following diagnostic mode on the scan tool:
ACP_PRESS PCM PID. No
• With the manifold gauge set connected, compare the pressure INSTALL a new A/C pressure
readings of the manifold gauge set and the ACP_PRESS PID. transducer. TEST the system
• Are the pressure values of the manifold gauge set and the for normal operation.
ACP_PRESS PID similar?
M2 CHECK THE A/C EVAPORATOR TEMPERATURE
(EVAP_TEMP) HVAC PID
Yes
• Allow the vehicle exterior and interior to stabilize to an ambient For Fusion equipped with
temperature above 16Â°C (60Â°F). navigation and all MKZ
• Enter the following diagnostic mode on the scan tool: vehicles, GO to M4 .
EVAP_TEMP HVAC PID.
• Does the EVAP_TEMP HVAC PID read similar to the For Fusion not equipped with
ambient temperature? navigation , GO to M3 .
No
INSTALL a new A/C
evaporator discharge
temperature sensor. TEST the
M3 CHECK THE (A/C) SWITCH (CC_SW_AC) HVAC PID
WITH THE A/C ON
Yes
• Enter the following diagnostic mode on the scan tool: GO to M6 .
CC_SW_AC HVAC PID.
No
PINPOINT TEST M: THE AIR CONDITIONING (A/C) IS INOPERATIVE 4877

• Select PANEL press the A/C button (indicator on) on the HVAC GO to M12 .
module.
• Does the CC_SW_AC HVAC PID read Active?
M4 CHECK THE A/C INDICATOR WITH THE A/C ON
Yes
NOTE: Before carrying out this test step, be sure all other GO to M6 .
FCIM button functions are operational. If all other buttons
operate correctly, continue with this test step. If multiple buttons No
are inoperative and DTC U0256:00 is not present, install a new GO to M5 .
FCIM . Test the system for normal operation. If DTC U0256:00
is present, diagnose the DTC first.
• Select PANEL press the A/C button on the HVAC module.

• Does the A/C indicator illuminate when the A/C button is
pressed?
M5 CHECK THE MAX A/C OPERATION
Yes
NOTE: Before carrying out this test step, be sure all other ACM INSTALL a new FCIM .
touch screen functions are operational. If all other touch screen TEST the system for normal
functions operate correctly, continue with this test step. If operation.
multiple touch screen functions are inoperative and DTC
U0163:00 is not present, install a new ACM . Test the system No
for normal operation. If DTC U0163:00 is present, diagnose the GO to M12 .
DTC first.
• Select MAX A/C on the next generation navigation screen.

• Does the A/C operate when MAX A/C is selected?
M6 CHECK THE AIR CONDITIONING COMPRESSOR
COMMANDED STATE (ACC_CMD) PCM PID WITH THE A/C
ON
Yes
• Enter the following diagnostic mode on the scan tool: GO to M7 .
ACC_CMD PCM PID.
• Does the ACC_CMD PCM PID read ON? No
GO to M13 .
M7 CHECK THE VOLTAGE AT THE A/C COMPRESSOR
CLUTCH FIELD COIL
Yes
• Ignition OFF. GO to M8 .
• Disconnect: A/C Compressor Clutch Field Coil C100.
• Ignition ON. No
• Select PANEL and A/C on the HVAC module. GO to M10 .
• Measure the voltage between A/C compressor clutch field coil
C100-B, circuit CH401 (VT/WH), harness side and ground.


M8 CHECK THE GROUND AT THE A/C COMPRESSOR
CLUTCH FIELD COIL
Yes
• Measure the resistance between A/C compressor clutch field coil
C100-A, circuit GD121 (BK/YE), harness side and ground. No
REPAIR circuit GD121
(BK/YE) for an open. TEST
operation.

M9 CHECK THE A/C COMPRESSOR CLUTCH AIR GAP
Yes
• Measure the A/C compressor clutch air gap at 3 equally spaced ADJUST the A/C compressor
locations between the clutch hub and the A/C compressor clutch clutch gap. REFER to Air
pulley. Conditioning (A/C) Clutch Air
Gap Adjustment in this
normal operation.
No
INSTALL a new A/C
compressor clutch field coil.
operation.
• Is the A/C compressor clutch air gap greater than 0.6 mm
(0.024 in)?
M10 CHECK THE A/C CLUTCH RELAY FOR VOLTAGE
Yes
• Disconnect: A/C Clutch Relay.
• Ignition ON. No
• Measure the voltage between A/C clutch relay socket, circuit VERIFY Battery Junction Box
SBB25 (RD) and ground. (BJB) fuse 25 (10A) is OK. If
OK, REPAIR circuit SBB25
(RD) for an open. TEST the
system for normal operation. If
not OK, REFER to the Wiring
Diagrams manual to identify

the possible causes of the

circuit short.

M11 CHECK CIRCUIT CH401 (VT/WH) FOR AN OPEN
Yes
• Ignition OFF. CARRY OUT the A/C clutch
• Measure the resistance between A/C clutch relay socket, circuit relay component test. If the
CH401 (VT/WH) and A/C compressor clutch field coil C100-B, relay tests OK, GO to M13 .
circuit CH401 (VT/WH), harness side.
No
REPAIR circuit CH401
(VT/WH) for an open. TEST
operation.

M12 CHECK THE MODULE CONNECTION
Yes
REPEAT the self-test. TEST
operation.
M13 CHECK THE PCM CONNECTION
Yes
• Disconnect all the PCM connectors. INSTALL a new PCM. TEST
• Inspect the module connectors for: the system for normal
• Connect and correctly seat all the PCM connectors. The system is operating
• Clear the DTCs. correctly at this time. The
• Operate the system and verify the concern is still present. concern may have been caused
• Is the concern still present? by a loose or corroded
connector.

Pinpoint Test N: The Air Conditioning (A/C) is Always On â A/C Compressor Does Not Cycle
Normal Operation
been selected.

• PCM
• evaporator discharge air temperature sensor
• A/C control relay
• A/C clutch air gap
• Evaporator core seals
PINPOINT TEST N: THE AIR CONDITIONING (A/C) IS ALWAYS ON â A/C COMPRESSOR DOES NOT CYCLE

N1 CHECK THE A/C EVAPORATOR TEMPERATURE
Yes
NOTE: Before carrying out the following test, diagnose any GO to N3 .
HVAC, PCM or Instrument Cluster (IC) DTCs.
No
NOTE: CHECK On-Line Automotive Service Information GO to N2 .
System (OASIS) for any applicable Technical Service
Bulletins (TSBs). If a Technical Service Bulletin (TSB)
exists for this concern, discontinue this test and follow the
TSB instructions. If no TSBs address this concern, continue
with this test.
• Ignition ON.

• Allow the vehicle exterior and interior to stabilize to an

ambient temperature between 15Â°C (60Â°F) and 32Â°C
(90Â°F).
EVAP_TEMP HVAC PID.
• Does the EVAP_TEMP HVAC PID read similar to the
ambient temperature?
N2 CHECK THE EVAPORATOR DISCHARGE AIR
TEMPERATURE SENSOR RESISTANCE
Yes
• Ignition OFF. GO to N9 .
• Disconnect: For Electronic Manual Temperature Control
(EMTC) Systems, Inline C211. No
• Disconnect: For Dual Automatic Temperature Control INSTALL a new evaporator
(DATC) Systems, Inline C213. discharge air temperature sensor.
• Measure the resistance between: TEST the system for normal
♦ For EMTC Systems, inline C211-13, circuit VH406 operation.
(VT/BN), HVAC case harness side and inline
C211-15, circuit RH111 (GY/BU), HVAC case
harness side.
♦ For DATC Systems, inline C213-13, circuit VH406
(VT/BN), HVAC case harness side and inline
C213-15, circuit RH111 (GY/BU), HVAC case
harness side.
• Compare the measurement to the chart and table of the

Evaporator Discharge Air Temperature Sensor component
test in this section.
temperatures?
N3 CHECK THE AIR CONDITIONING COMPRESSOR
COMMANDED STATE (ACC_CMD) PCM PID WITH THE
A/C OFF
Yes
• Enter the following diagnostic mode on the scan tool: GO to N8 .
ACC_CMD PCM PID.
GO to N4 .
N4 CHECK FOR VOLTAGE TO THE A/C COMPRESSOR
CLUTCH FIELD COIL
PINPOINT TEST N: THE AIR CONDITIONING (A/C) IS ALWAYS ON â A/C COMPRESSOR4882

DOES NOT

• Disconnect: A/C Compressor Clutch Field Coil C100. GO to N5 .
• Ignition ON.
• Select the OFF position on the HVAC module. No
• Measure the voltage between A/C compressor clutch field ADJUST the A/C compressor
coil C100-B, circuit CH401 (VT/WH), harness side and clutch gap. REFER to Air
ground. Conditioning (A/C) Clutch Air
Gap Adjustment in this section.
operation.

N5 CHECK CIRCUIT CH401 (VT/WH) FOR A SHORT TO
VOLTAGE
Yes
• Ignition OFF. REPAIR circuit CH401 (VT/WH)
• Disconnect: A/C Clutch Relay. for a short to voltage. TEST the
• Ignition ON. system for normal operation.
• Measure the voltage between A/C compressor clutch field
coil C100-B, circuit CH401 (VT/WH), harness side and No
ground. INSTALL a new A/C clutch relay.
operation. If the concern is still
present, GO to N6 .

N6 CHECK THE EVAPORATOR DISCHARGE AIR
TEMPERATURE SENSOR MOUNTING
Yes
• Remove the instrument panel. For additional information, GO to N7 .
• Inspect the evaporator discharge air temperature sensor for: No
♦ damage. INSTALL a new evaporator
♦ correct mounting. discharge air temperature sensor.
♦ damaged mounting tabs. TEST the system for normal
• Is the sensor and mounting correct and free of damage? operation.
N7 CHECK THE EVAPORATOR CORE SEALS
Yes
• Remove the heater core and evaporator core housing. For GO to N9 .
• Remove the evaporator core. For additional information, No
refer to Section 412-01 . CORRECT the evaporator core
PINPOINT TEST N: THE AIR CONDITIONING (A/C) IS ALWAYS ON â A/C COMPRESSOR4883

DOES NOT
• Inspect the evaporator core seals for: seal alignment or INSTALL a new
♦ misalignment. evaporator core. REFER to
♦ damage. Section 412-01 . TEST the system
♦ loose fit. for normal operation.
• Is the evaporator seal mounting tight, correct and free of
damage?
N8 CHECK THE PCM CONNECTION
Yes
• Disconnect all the PCM connectors. INSTALL a new PCM. TEST the
• Inspect the module connectors for: system for normal operation.
♦ corrosion.
♦ damaged terminals. The system is operating correctly
• Connect and correctly seat all the PCM connectors. at this time. The concern may have
• Clear the DTCs. been caused by a loose or corroded
• Operate the system and verify the concern is still present. connector.
N9 CHECK THE HVAC MODULE CONNECTION
Yes
• Inspect the HVACmodule connectors for: INSTALL a new HVAC module.
♦ corrosion. REFER to Section 412-01 . TEST
♦ pushed-out terminals. the system for normal operation.
• Connect and correctly seat all the HVAC module connectors. No
• Clear the DTCs. The system is operating correctly
• Operate the system and verify the concern is still present. at this time. The concern may have
• Is the concern still present? been caused by a loose or corroded
connector.
Pinpoint Test O: The Air Conditioning (A/C) is Always On â A/C Mode Always Commanded ON
Normal Operation
been selected.


• PCM
• HVAC module
PINPOINT TEST O: THE AIR CONDITIONING (A/C) IS ALWAYS ON â A/C MODE ALWAYS COMMANDED ON
NOTE: Before carrying out the following test, diagnose any HVAC, PCM or Instrument Cluster (IC) DTCs.

O1 CHECK THE AIR CONDITIONING REQUEST SIGNAL
(AC_REQ) PCM PID WITH THE A/C OFF
Yes
• Ignition ON. If the vehicle is equipped with
• Enter the following diagnostic mode on the scan tool: AC_REQ navigation, GO to O3 .
PCM PID.
• Select PANEL press the A/C button (indicator off) on the HVAC If the vehicle is not equipped
module. with navigation, GO to O2 .
• Does the AC_REQ PCM PID read YES?
No
GO to O6 .
O2 CHECK THE AIR CONDITIONING SWITCH STATUS
(CC_SW_AC) HVAC PID WITH THE A/C OFF
Yes
• Enter the following diagnostic mode on the scan tool: GO to O6 .
CC_SW_AC HVAC PID.
• Select PANEL press the A/C button (indicator off) on the HVAC No
module. GO to O5 .
• Does the CC_SW_AC HVAC PID read Inactive?
O3 CHECK THE A/C INDICATOR WITH THE A/C OFF
Yes
NOTE: Before carrying out this test step, be sure all other FCIM GO to O5 .
button functions are operational. If all other buttons operate
correctly, continue with this test step. If multiple buttons are No
inoperative and DTC U0256:00 is not present, install a new GO to O4 .
FCIM . Test the system for normal operation. If DTC U0256:00
is present, diagnose the DTC first.
• Select PANEL press the A/C button (indicator off) on the HVAC
module.
• Does the A/C indicator turn off when the A/C button is
pressed?
O4 CHECK THE MAX A/C OPERATION
Yes
NOTE: Before carrying out this test step, be sure all other ACM INSTALL a new FCIM .
touch screen functions are operational. If all other touch screen TEST the system for normal
PINPOINT TEST O: THE AIR CONDITIONING (A/C) IS ALWAYS ON â A/C MODE ALWAYS4885
COMMAND
functions operate correctly, continue with this test step. If operation.

multiple touch screen functions are inoperative and DTC
U0163:00 is not present, install a new ACM . Test the system for No
normal operation. If DTC U0163:00 is present, diagnose the DTC GO to O5 .
first.
• Select MAX A/C on the next generation navigation screen.

• Does the A/C turn off when MAX A/C is selected?
O5 CHECK THE MODULE CONNECTION
Yes
concern may have been
caused by a loose or corroded
operation.
O6 CHECK THE PCM CONNECTION
Yes
• Disconnect all the PCM connectors. INSTALL a new PCM. TEST
• Inspect the module connectors for: the system for normal
• Connect and correctly seat all the PCM connectors. The system is operating
• Clear the DTCs. correctly at this time. The
• Operate the system and verify the concern is still present. concern may have been
connector.
Pinpoint Test P: Temperature Control is Inoperative/Does Not Operate Correctly
Normal Operation
Under normal operation, to rotate the temperature blend door actuator clockwise, the HVAC module supplies
voltage to the temperature blend door actuators through the door actuator feed A circuits, and supplies ground
through the door actuator feed B circuits. To rotate the temperature blend door actuator counterclockwise, the
HVAC module reverses the voltage and ground circuits.
The temperature blend door actuator feedback resistors are supplied a ground from the HVAC module by the
temperature blend door actuator return circuits and a 5-volt reference voltage on the temperature blend door
actuator reference circuits. The HVAC module reads the voltage on the temperature blend door actuator

feedback circuits to determine the temperature blend door actuator position by the position of the actuator
feedback resistor wiper arm.
Door actuator feed A circuits

♦ LH blend â CH238 (YE/OG)
♦ RH blend â CH212 (BU/OG)
Door actuator feed B circuits

♦ LH blend â CH239 (BU/WH)
♦ RH blend â CH213 (BN/GN)
Door actuator return circuits

♦ LH blend â RH111 (GY/BU)
♦ RH blend â RH111 (GY/BU)
Door actuator reference circuits

♦ LH blend â LH111 (BN/WH)
♦ RH blend â LH111 (BN/WH)
Door actuator feedback circuits

♦ LH blend â VH440 (BU/BN)
♦ RH blend â VH411 (VT/GN)

The module senses no changes in the feedback circuit
• B1081:07 â Left Temperature Damper when motor movement is commanded and no motor
Motor: Mechanical Failures DTCs are present.
The module senses excessive voltage drop on the sensor
• B1081:11 â Left Temperature Damper reference voltage circuit, indicating a short directly to
Motor: Circuit Short to Ground ground.
The module senses no voltage drop on the sensor
• B1081:12 â Left Temperature Damper reference voltage circuit, indicating an open circuit.
Motor: Circuit Short to Battery
• B1081:13 â Left Temperature Damper reference voltage circuit, indicating a short directly to
Motor: Circuit Open ground.
The module senses no changes in the feedback circuit
• B1082:07 â Right Temperature Damper when motor movement is commanded and no motor
Motor: Mechanical Failures DTCs are present.
• B1082:11 â Right Temperature Damper reference voltage circuit, indicating a short directly to
Motor: Circuit Short to Ground ground.

• B1082:12 â Right Temperature Damper The module senses no voltage drop on the sensor
Motor: Circuit Short to Battery reference voltage circuit, indicating an open circuit.
• B1082:13 â Right Temperature Damper reference voltage circuit, indicating a short directly to
Motor: Circuit Open ground.
• B11E5:11 â Left HVAC Damper reference voltage circuit, indicating an open circuit.
Position Sensor: Circuit Short to Ground
• B11E5:15 â Left HVAC Damper reference voltage circuit, indicating a short directly to
Position Sensor: Circuit Short to Battery or ground.
Open
• B11E6:11 â Right HVAC Damper reference voltage circuit, indicating an open circuit.
Position Sensor: Circuit Short to Ground
• B11E6:15 â Right HVAC Damper reference voltage circuit, indicating a short directly to
Position Sensor: Circuit Short to Battery or ground.
Open

• HVAC module
PINPOINT TEST P: TEMPERATURE CONTROL IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

P1 CHECK THE HVAC MODULE FOR DTCs
Yes
• Ignition ON. For DTC B1081:07 or B1082:07 ,
• Check the HVAC module for DTCs. INSPECT for binding/damaged linkage or
• Are any DTCs present? door. REPAIR as necessary. If no condition
is found, INSTALL a new door actuator.
For DTC B1081:12 or B1082:12 , GO to

P2 .
For DTC B1081:13 or B1082:13 , GO to

P3 .
For DTC B1081:11 or B1082:11 , GO to

P4 .
For DTC B11E5:15 or B11E6:15 , GO to

P6 .

4888
For DTC B11E5:11 or B11E6:11 , GO to

P10 .
No
INSPECT for broken linkage or door.
REPAIR as necessary. If no condition is
found, GO to P13 .
P2 CHECK THE ACTUATOR MOTOR DRIVE
CIRCUITS FOR A SHORT TO POWER
Yes
• Ignition OFF. REPAIR the circuit(s) for a short to power.
• Disconnect: HVAC Module â EMTC C2357a. CLEAR the DTCs. REPEAT the self-test.
• Disconnect: HVAC Module â Dual Automatic TEST the system for normal operation.
Temperature Control (DATC) C2356a.
• Disconnect: HVAC Module â DATC C2356b. No
• Ignition ON. GO to P5 .
♦ For DTC B1081:12 , HVAC module â
EMTC C2357a-22 or HVAC module â
DATC C2356a-22, circuit CH238
(YE/OG), harness side.
DATC C2356b-26, circuit CH212
(BU/OG), harness side.

(BN/GN), harness side.
• Are any voltages present?


4889
NOTE: Due to limited connector accessibility, Yes

before carrying out this test step, visually inspect GO to P13 .
the wiring between the HVAC module and actuator
for opens or shorts. If no damage is visually No
evident, proceed with the test. REPAIR the circuit(s) for an open. CLEAR
the DTCs. REPEAT the self-test. TEST the
• Ignition OFF. system for normal operation.
• Disconnect: For DTC B1081:00 , LH Temperature
Blend Door Actuator C2091.
• Disconnect: For DTC B1082:00 , RH Temperature
Blend Door Actuator C2092 .
• Measure the resistance between:
(YE/OG), harness side and LH temperature
blend door actuator C2091-5, circuit
CH238 (YE/OG), harness side.
(BU/OG), harness side and RH temperature
CH212 (BU/OG), harness side.
• Measure the resistance between:

(BU/WH), harness side and LH
temperature blend door actuator C2091-6,
circuit CH239 (BU/WH), harness side.
(BN/GN), harness side and RH temperature
CH213 (BN/GN), harness side.

4890

Yes
• Ignition OFF. GO to P5 .
• Disconnect: HVAC Module â DATC C2356b. REPAIR the circuit(s) for a short to ground.
• Measure the resistance between ground and: CLEAR the DTCs. REPEAT the self-test.
♦ For DTC B1081:11 , HVAC module â TEST the system for normal operation.
(YE/OG), harness side.
(BU/OG), harness side.
• Measure the resistance between ground and:

(BN/GN), harness side.


4891
NOTE: Due to limited connector accessibility, Yes

before carrying out this test step, visually inspect GO to P13 .
the wiring between the HVAC module and actuator
for opens or shorts. If no damage is visually No
evident, proceed with the test. REPAIR circuit(s) for a short together.
• Ignition OFF. TEST the system for normal operation.
• Disconnect: For DTC B1081:11 , LH Temperature
Blend Door Actuator C2091.
• Disconnect: For DTC B1082:11 , RH Temperature
Blend Door Actuator C2092 .
For DTC B1081:11.
• NOTE: For DTC B1081:11 .

â EMTC C2357a-21 or HVAC module â
DATC C2356a-21, circuit CH239 (BU/WH),
C2357a-22 or HVAC module â DATC
C2356a-22, circuit CH238 (YE/OG), harness side.
For DTC B1082:11.
• NOTE: For DTC B1082:11 .

â DATC C2356b-25, circuit CH213 (BN/GN),
harness side and HVAC module â DATC
C2356b-26, circuit CH212 (BU/OG), harness side.
P6 CHECK CIRCUIT VH441 (WH/BN) OR VH440
(BU/BN) FOR AN OPEN
Yes
NOTE: Due to limited connector accessibility, GO to P7 .
before carrying out this test step, visually inspect
the wiring between the HVAC module and actuator No
for opens or shorts. If no damage is visually REPAIR circuit VH441 (WH/BN) or
evident, proceed with the test. VH440 (BU/BN) for an open. CLEAR the
For DTC B1081:11. 4892


• Disconnect: For DTC B11E5:15 , LH
Temperature Blend Door Actuator C2091.
• Disconnect: For DTC B11E6:15 , RH
Temperature Blend Door Actuator C2092 .
• Measure the resistance between the following:
♦ For DTC B11E5:15 , HVAC module â
DATC C2356a-7, circuit VH440 (BU/BN),
harness side and LH temperature blend
door actuator C2091-9, circuit VH440
(BU/BN), harness side.
DATC C2356b-16, circuit VH441
(WH/BN), harness side and RH
temperature blend door actuator C2092-9,
circuit VH441 (WH/BN), harness side.

P7 CHECK CIRCUIT VH440 (BU/BN) OR VH441
(WH/BN) FOR A SHORT TO POWER
Yes
• Ignition ON. REPAIR circuits VH441 (WH/BN) or
• Measure the voltage between ground and the VH440 (BU/BN) for a short to power.
following: CLEAR the DTCs. REPEAT the self-test.
♦ For DTC B11E5:15 , HVAC module â TEST the system for normal operation.
DATC C2356a-7, circuit VH440 (BU/BN), No
harness side. GO to P8 .

P8 CHECK CIRCUIT LH111 (BN/WH) FOR A
SHORT TO CIRCUIT VH441 (WH/BN) OR VH440
(BU/BN)
For DTC B1082:11. 4893


• Measure the resistance between HVAC module GO to P9 .
DATC C2356a-11, circuit LH111 (BN/WH) and No
the following: REPAIR circuits LH111 (BN/WH) and
♦ For DTC B11E5:15 , HVAC module â VH441 (WH/BN) or VH440 (BU/BN) for a
EMTC C2357a-7 or HVAC module â short together. CLEAR the DTCs. REPEAT
DATC C2356a-7, circuit VH440 (BU/BN), the self-test. TEST the system for normal
harness side. operation.

P9 CHECK THE ACTUATOR RETURN CIRCUIT
RH111 (GY/BU) FOR AN OPEN
Yes
• Measure the resistance between HVAC module GO to P13 .
DATC C2356a-10, circuit RH111 (GY/BU) and No
the following: REPAIR circuit RH111 (GY/BU) for an
♦ For DTC B11E5:15 , LH temperature open. CLEAR the DTCs. REPEAT the
blend door actuator C2091-8, circuit self-test. TEST the system for normal
RH111 (GY/BU), harness side. operation.
♦ For DTC B11E6:15 , RH temperature
RH111 (GY/BU), harness side.

P10 CHECK CIRCUIT VH440 (BU/BN) OR VH441
(WH/BN) FOR A SHORT TO GROUND
Yes
• Disconnect: HVAC Module â DATC C2356b. REPAIR circuit VH441 (WH/BN) or
• Measure the resistance between ground and the VH440 (BU/BN) for a short to ground.
following: CLEAR the DTCs. REPEAT the self-test.
For DTC B1082:11. 4894

♦ For DTC B11E5:11 , HVAC module â TEST the system for normal operation.
harness side.

P11 CHECK CIRCUIT RH111 (GY/BU) FOR A
SHORT TO CIRCUIT VH441 (WH/BN) OR VH440
(BU/BN)
Yes
NOTE: Due to limited connector accessibility, GO to P12 .
before carrying out this test step, visually inspect
the wiring between the HVAC module and actuator No
for opens or shorts. If no damage is visually REPAIR circuits RH111 (GY/BU) and
evident, proceed with the test. VH441 (WH/BN) or VH440 (BU/BN) for a
short together. CLEAR the DTCs. REPEAT
• Disconnect: For DTC B11E5:11 , LH the self-test. TEST the system for normal
Temperature Blend Door Actuator C2091. operation.
• Disconnect: For DTC B11E6:11 , RH
Temperature Blend Door Actuator C2092 .
DATC C2356a-10, circuit RH111 (GY/BU) and
the following:
harness side.

P12 CHECK CIRCUIT LH111 (BN/WH) FOR AN
OPEN
For DTC B1082:11. 4895

• Measure the resistance between HVAC module Yes

â EMTC C2357a-11 or HVAC module â GO to P13 .
DATC C2356a-11, circuit LH111 (BN/WH) and
the following: No
♦ For DTC B11E5:11 , LH temperature REPAIR circuit LH111 (BN/WH) for an
blend door actuator C2091-10, circuit open. CLEAR the DTCs. REPEAT the
LH111 (BN/WH), harness side. self-test. TEST the system for normal
♦ For DTC B11E6:11 , RH temperature operation.
LH111 (BN/WH), harness side.

P13 CHECK THE ACTUATOR CONNECTION
Yes
• Disconnect the actuator connector. CARRY OUT the Temperature Blend Door
• Check for: Actuator component test in this section. If
♦ corrosion. the actuator tests OK, GO to P14 .
• Connect and correctly seat the actuator connector. The system is operating correctly at this
• Clear the DTCs. time. The concern may have been caused by
• Operate the system and verify the concern is still a loose or corroded connector. CLEAR the
present. DTCs. TEST the system for normal
• Is the concern still present? operation.
P14 MODULE ACTUATOR POSITION
CALIBRATION
Yes
NOTE: The purpose of the module actuator INSTALL a new HVAC module. REFER to
position calibration is to allow the HVAC module Section 412-01 . TEST the system for
to reinitialize and calibrate the actuator stop points. normal operation.
To carry out the calibration, follow the steps below.
No
• Ignition OFF. The system is now operating correctly at
• Inspect the module connectors for: this time. The concern may have been
♦ corrosion. caused by a foreign object in the HVAC
♦ pushed-out terminals. case or temporary binding that restricted
♦ damaged terminals. actuator door travel. CHECK any actuator
• Connect and correctly seat all the HVAC module external linkage. If condition recurs,
connectors. INSPECT actuator linkage and door for
• Ignition ON. binding and CHECK HVAC case for
• Clear the DTCs. foreign objects.
• Select any position except OFF.
• NOTE: The HVAC module will now initialize and
calibrate the actuators. Calibration of the actuators
will take approximately 30 seconds.
For DTC B1082:11. 4896


present.
Pinpoint Test Q: The Blower Motor is Inoperative â EMTC
Normal Operation
Under normal operation, the blower motor relay coil receives ignition voltage through circuit CBP45 (YE).
The coil receives ground from the HVAC module â Electronic Manual Temperature Control (EMTC)
through circuit CH123 (VT/GN) if any function selector position but OFF is selected. Voltage is supplied to
the relay switch contact through circuit SBB06 (BN/RD). When the relay coil is energized, voltage is
delivered to the blower motor through circuit CH402 (YE/GN). Ground for the blower motor is provided
through circuit CH426 (YE/OG) from the blower resistor or the blower switch (HI). The blower resistor and
blower switch is grounded through circuit GD115 (BK/GY).
• DTC B10AF:12 (Blower Fan Relay: Circuit Short to Battery) â The module senses excessive
voltage on the relay coil ground circuit, indicating a short directly to voltage.
• DTC B10AF:14 (Blower Fan Relay: Circuit Short to Ground or Open) â The module senses no
voltage on the relay coil ground circuit, indicating an open or a short directly to ground.

• Fuse(s)
• Blower motor
PINPOINT TEST Q: THE BLOWER MOTOR IS INOPERATIVE â EMTC

Q1 CHECK THE HVAC MODULE FOR DTCs
Yes
• Ignition ON. For B10AF:12 , REPAIR circuit CH123
• Check the HVAC module for DTCs. (VT/GN) for a short to voltage. CLEAR the
• Are any DTCs present? DTCs. REPEAT the self-test. TEST the system
For B10AF:14 , CARRY OUT the blower

motor relay component test.

Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ) for
component testing.
If the relay tests OK, GO to Q2 .
No

GO to Q3 .
Q2 CHECK THE RELAY COIL SUPPLY
VOLTAGE
Yes
• Ignition OFF. REPAIR circuit CH123 (VT/GN) for an open.
• Disconnect: Blower Motor Relay. TEST the system for normal operation.
• Ignition ON.
• Measure the voltage between blower motor No
relay socket pin 86, circuit CBP45 (YE) and VERIFY Smart Junction Box (SJB) fuse 45 (5A)
ground. is OK. If OK, REPAIR circuit CBP45 (YE) for
an open. TEST the system for normal operation.

Q3 CHECK CIRCUIT CH426 (YE/OG) FOR
GROUND
Yes
• Ignition OFF. GO to Q5 .
• Disconnect: Blower Motor C288.
• Turn the function selector switch to the No
PANEL position. GO to Q4 .
• Turn the blower motor switch to the HI
position.
• Measure the resistance between blower motor
connector C288-B, circuit CH426 (YE/OG),

Q4 CHECK CIRCUIT CH426 (YE/OG) FOR AN
OPEN
Yes
• Disconnect: HVAC Module â EMTC REPAIR circuit GD115 (BK/GY) for an open.
C2357b. TEST the system for normal operation.
• Measure the resistance between HVAC
module â EMTC C2357b-2, circuit CH426 No
(YE/OG), harness side and blower motor REPAIR circuit CH426 (YE/OG) for an open.
C288-B, circuit CH426 (YE/OG), harness TEST the system for normal operation.
side.
PINPOINT TEST Q: THE BLOWER MOTOR IS INOPERATIVE â EMTC 4898


Q5 CHECK BLOWER MOTOR CIRCUIT
CH402 (YE/GN) FOR VOLTAGE
Yes
• Ignition ON. INSTALL a new blower motor. REFER to
• Measure the voltage between blower motor Section 412-01 . TEST the system for normal
C288-A, circuit CH402 (YE/GN), harness side operation.
and ground.
No
GO to Q6 .

Q6 CHECK CIRCUIT SBB35 (BU/RD) FOR
VOLTAGE
Yes
• Ignition OFF. CARRY OUT the blower motor relay
• Disconnect: Blower Motor Relay. component test.
• Ignition ON.
• Measure the voltage between blower motor Refer to Wiring Diagrams Cell 149 (
relay socket pin 30, circuit SBB35 (BU/RD) Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ) for
and ground. component testing.
If the relay tests OK, REPAIR circuit CH402

(YE/GN) for an open. TEST the system for
normal operation.
No
VERIFY Battery Junction Box (BJB) fuse 35
(40A) is OK. If OK, REPAIR circuit SBB35
(BU/RD) for an open. TEST the system for
normal operation.
Pinpoint Test R: The Blower Motor Does Not Operate Correctly â EMTC
PINPOINT TEST Q: THE BLOWER MOTOR IS INOPERATIVE â EMTC 4899

Normal Operation
Under normal operation, the blower motor is provided ground from the blower resistor through circuit CH426
(YE/OG). The resistor gets a ground from circuit GD115 (BK/GY) in the lowest blower setting. In MED-LO
and MED-HI the resistor gets ground from the blower motor switch through circuit CH428 (GN/WH) or
CH429 (GY/BN), depending on selected speed. In HI, the blower motor is grounded directly through the
blower motor switch from circuit CH426 (YE/OG) to circuit GD115 (BK/GY). The blower switch receives its
ground from circuit GD115 (BK/GY).

• HVAC module â Electronic Manual Temperature Control (EMTC)
PINPOINT TEST R: THE BLOWER MOTOR DOES NOT OPERATE CORRECTLY â EMTC
Result / Action to
Test Step
Take
R1 CHECK THE HVAC MODULE FOR DTCs
Yes
• Ignition ON. REPAIR circuit
• Check the HVAC module for DTCs. CH123 (VT/GN) for a
• Is DTC B10AF:14 present? short to ground.
CLEAR the DTCs.
REPEAT the self-test.
TEST the system for
normal operation.
No
GO to R2 .
R2 CHECK THE BLOWER MOTOR OPERATION
Yes
• Ignition ON. If the blower motor
• Turn the function selector switch to the FLOOR position. does not operate in HI
• Select all blower speed positions. setting only, GO to
• Does the blower motor operate in any position? R3 .
If the blower motor

does not operate in
LO setting only, GO
to R4 .
If the blower motor

does not operate in
MED-LO or MED-HI
setting only, GO to
R5 .
If the blower motor

operates in HI setting
only, GO to R7 .
If the blower motor

operates in LO setting
only, GO to R8 .
For all other

symptoms, GO to R9 .
No
GO to Pinpoint Test Q
.
R3 CHECK CIRCUIT CH426 (YE/OG) FOR AN OPEN
Yes
• Ignition OFF. INSTALL a new
• Disconnect: HVAC Module â EMTC C2357b. HVAC module. TEST
• Disconnect: Blower Motor C288. the system for normal
• Measure the resistance between HVAC module â EMTC C2357b-2, operation.
circuit CH426 (YE/OG), harness side and blower motor C288-B, circuit
CH426 (YE/OG), harness side. No
REPAIR circuit
CH426 (YE/OG) for
an open. TEST the
system for normal
operation.

R4 CHECK BLOWER MOTOR RESISTOR GROUND CIRCUIT GD115
(BK/GY) FOR AN OPEN
Yes
• Disconnect: Blower Motor Resistor C1228. blower motor resistor.
• Measure the resistance between blower motor resistor C1228-D, circuit REFER to Section
GD115 (BK/GY), harness side and ground. 412-01 . TEST the
system for normal
operation.
No
REPAIR circuit
GD115 (BK/GY) for
an open. TEST the
system for normal
operation.
R5 CHECK CIRCUIT CH428 (GN/WH) OR CH429 (GY/BN) FOR
GROUND
PINPOINT TEST R: THE BLOWER MOTOR DOES NOT OPERATE CORRECTLY â EMTC 4901
NOTICE: The following step uses a test light to stimulate normal Yes
circuit loads. Use only the test light recommended in the Special INSTALL a new
Tools table at the beginning of this section or equivalent. To avoid blower motor resistor.
connector terminal damage, use the Flex Probe kit for the test light TEST the system for
probe connection to the vehicle. Do not use the test light probe normal operation.
directly on any connector.
No
• Ignition OFF. GO to R6 .
• Disconnect: Blower Motor Resistor C1228.
• Ignition ON.
For MED-LO inoperative.
• For MED-LO inoperative : With the blower motor switch in the

MED-LO speed position, connect a 12-volt test lamp between blower
motor resistor C1228-C, circuit CH426 (YE/OG), harness side and
blower motor resistor C1228-A, circuit CH428 (GN/WH), harness side.
For MED-HI inoperative.
• For MED-HI inoperative : With the blower motor switch in the

MED-HI speed position, connect a 12-volt test lamp between blower
motor resistor C1228-C, circuit CH426 (YE/OG), harness side and
blower motor resistor C1228-B, circuit CH429 (GY/BN), harness side.
• Does the test lamp illuminate?
R6 CHECK CIRCUIT CH428 (GN/WH) OR CH429 (GY/BN) FOR AN
OPEN
Yes
• Ignition OFF. CARRY OUT the
• Disconnect: HVAC Module â EMTC C2357b. Blower Motor
Resistor component
For MED-LO inoperative. test in this section. If
the resistor tests OK,
INSTALL a new
blower motor switch.
TEST the system for
normal operation.
No
• For MED-LO inoperative , measure the resistance between HVAC REPAIR circuit
module â EMTC C2357b-4, circuit CH428 (GN/WH), harness side CH428 (GN/WH) or
For MED-LO inoperative. 4902

and blower motor resistor C1228-A, circuit CH428 (GN/WH), harness CH429 (GY/BN) for
side. an open. TEST the
system for normal
For MED-HI inoperative. operation.
• For MED-HI inoperative , measure the resistance between HVAC

module â EMTC C2357b-3, circuit CH429 (GY/BN), harness side and
blower motor resistor C1228-B, circuit CH429 (GY/BN), harness side.
R7 CHECK CIRCUIT CH426 (YE/OG) FOR AN OPEN
Yes
• Disconnect: Blower Motor Resistor C1228. blower motor resistor.
• Disconnect: Blower Motor C288. TEST the system for
• Measure the resistance between blower motor resister C1228-C, circuit normal operation.
CH426 (YE/OG), harness side and blower motor C288-B, circuit CH426
(YE/OG), harness side. No
REPAIR circuit
CH426 (YE/OG) for
an open. TEST the
system for normal
operation.

R8 CHECK THE BLOWER MOTOR SWITCH CIRCUIT GD115
(BK/GY) FOR AN OPEN
Yes
• Measure the resistance between HVAC Module â EMTC C2357b-1, INSTALL a new
circuit GD115 (BK/GY), harness side and ground. HVAC module. TEST
operation.
No
REPAIR circuit
GD115 (BK/GY) for
an open. TEST the
system for normal
operation.
R9 CHECK CIRCUITS CH426 (YE/OG), CH428 (GN/WH) AND CH429
(GY/BN) FOR A SHORT TO GROUND
For MED-LO inoperative. 4903


• Disconnect: Blower Motor C288. GO to R10 .
• Disconnect: Blower Motor Resistor C1228.
• Disconnect: HVAC Module â EMTC C2357b. No
• Measure the resistance between ground and blower motor resistor: REPAIR the affected
♦ C1228-A, circuit CH428 (GN/WH), harness side. circuit for a short to
♦ C1228-C, circuit CH426 (YE/OG), harness side. ground. TEST the
♦ C1228-B, circuit CH429 (GY/BN), harness side. system for normal
operation.

R10 CHECK THE BLOWER MOTOR CIRCUITS FOR SHORTS
TOGETHER
Yes
• Measure the resistance between blower motor resistor: CARRY OUT the
♦ C1228-A, circuit CH428 (GN/WH), harness side and C1228-C, Blower Motor
circuit CH426 (YE/OG), harness side. Resistor component
♦ C1228-A, circuit CH428 (GN/WH), harness side and C1228-B, test in this section. If
circuit CH429 (GY/BN), harness side. the resistor tests OK,
♦ C1228-C, circuit CH426 (YE/OG), harness side and C1228-B, INSTALL a new
circuit CH429 (GY/BN), harness side. HVAC module. TEST
operation.
No
REPAIR the affected
circuits. TEST the
system for normal
operation.
Pinpoint Test S: The Blower Motor is Inoperative â DATC
Normal Operation
Under normal operation, the blower motor relay coil receives a ground from the HVAC module through
circuit CH123 (VT/GN). The coil receives ignition voltage through circuit CBP45 (YE). Voltage is supplied
to the relay switch contact through circuit SBB06 (BN/RD). When the relay coil is energized, voltage is
delivered to the blower motor speed control through circuit CH402 (YE/GN). Ground for the blower motor
speed control is provided by circuit GD115 (BK/GY). Voltage for the motor is provided through circuit
VH301 (YE/BU) from the blower motor speed control. Ground for the motor is provided through circuit
VH219 (GY) from the blower motor speed control. The HVAC module sends a Pulse-Width Modulation
(PWM) signal to the blower motor speed control through circuit VH101 (WH/VT) to control the blower
For MED-HI inoperative. 4904

speed.
• DTC B10AF:12 (Blower Fan Relay: Circuit Short to Battery) â The module senses excessive
voltage on the relay coil ground circuit, indicating a short directly to voltage.
• DTC B10B9:12 (Blower Control: Circuit Short to Battery) â The module senses excessive voltage
on the blower motor control PWM circuit, indicating a short directly to voltage.
• DTC B10B9:14 (Blower Control: Circuit Short to Ground or Open) â The module senses no
voltage on the blower motor control PWM circuit, indicating an open or a short directly to ground.

• Fuse(s)
• HVAC module â Dual Automatic Temperature Control (DATC)
• Blower motor
PINPOINT TEST S: THE BLOWER MOTOR IS INOPERATIVE â DATC

S1 CHECK THE HVAC MODULE FOR DTCs
Yes
• Ignition ON. For DTC B10AF:12 , REPAIR circuit
• Check the HVAC module for DTCs. CH123 (VT/GN) for a short to voltage.
• Are any DTCs present? CLEAR the DTCs. REPEAT the
operation.
For DTC B10AF:14 , CARRY OUT

the Blower Motor Relay component
test.

Fusion/MKZ , Fusion Hybrid/MKZ
Hybrid ) for component testing.
If the relay tests OK, GO to S2 .
For DTC B10B9:14 , GO to S4 .
No
GO to S6 .
S2 CHECK THE RELAY COIL SUPPLY VOLTAGE
Yes
• Ignition OFF. GO to S3 .
• Disconnect: Blower Motor Relay.
• Ignition ON. No
• Measure the voltage between blower motor relay socket VERIFY Smart Junction Box (SJB)
pin 86, circuit CBP45 (YE) and ground. fuse 45 (5A) is OK. If OK, REPAIR

circuit CBP45 (YE) for an open.

operation. If not OK, REFER to the
Wiring Diagrams manual to identify
the possible causes of the circuit short.

S3 CHECK CIRCUIT CH123 (VT/GN) FOR AN OPEN
Yes
• Measure the resistance between blower motor relay No
socket pin 85, circuit CH123 (VT/GN) and HVAC REPAIR circuit CH123 (VT/GN) for
module â DATC C2356a-24, circuit CH123 an open. CLEAR the DTCs. REPEAT
(VT/GN), harness side. the self-test. TEST the system for
normal operation.

S4 CHECK CIRCUIT VH101 (WH/VT) FOR AN OPEN
Yes
• Disconnect: Blower Motor Speed Control C271.
• Measure the resistance between blower motor control REPAIR circuit VH101 (WH/VT) for
C271-B, circuit VH101 (WH/VT), harness side and an open. CLEAR the DTCs. REPEAT
HVAC module â DATC C2356a-14, circuit VH101 the self-test. TEST the system for
(WH/VT), harness side. normal operation.

S5 CHECK CIRCUIT VH101 (WH/VT) FOR GROUND
SIGNAL
PINPOINT TEST S: THE BLOWER MOTOR IS INOPERATIVE â DATC 4906

• Connect: HVAC Module â DATC C2356a. Yes

• Ignition ON. GO to S16 .
• Press the PANEL button on the HVAC module. Adjust
the blower motor setting to HI. No
• Measure the voltage between blower motor speed GO to S17 .
control C271-B, circuit VH101 (WH/VT), harness side
and blower motor speed control C271-C, circuit CH402

S6 CHECK FOR VOLTAGE TO THE BLOWER MOTOR
Yes
• Ignition OFF. INSTALL a new blower motor. TEST
• Disconnect: Blower Motor C288. the system for normal operation.
• Ignition ON.
• Measure the voltage between blower motor C288-A, No
circuit VH219 (GY), harness side and blower motor GO to S7 .
C288-B, circuit VH301 (YE/BU), harness side.

S7 CHECK FOR VOLTAGE TO THE BLOWER MOTOR
CONTROLLER
Yes
• Ignition ON. No
• Press the PANEL button on the HVAC module. GO to S14 .
• Measure the voltage between blower motor speed
control C271-C, circuit CH402 (YE/GN), harness side
and ground.


S8 CHECK CIRCUIT GD115 (BK/GY) FOR AN OPEN
Yes
• Measure the resistance between blower motor speed
control C271-A, circuit GD115 (BK/GY), harness side No
and ground. REPAIR circuit GD115 (BK/GY) for
an open. TEST the system for normal
operation.

S9 CHECK CIRCUIT VH101 (WH/VT) FOR GROUND
SIGNAL
Yes
• Press the PANEL button on the HVAC module. Adjust
the blower motor setting to HI. No
• Measure the voltage between blower motor speed GO to S17 .
control C271-2, circuit VH101 (WH/VT), harness side
and blower motor speed control C271-3, circuit CH402

S10 CHECK CIRCUITS VH219 (GY) AND VH301
(YE/BU) FOR AN OPEN
Yes
• Measure the resistance between the blower motor GO to S11 .
connector, harness side and blower motor speed control,
harness side using the following chart. No
REPAIR circuit VH219 (GY) or
VH301 (YE/BU) for an open. TEST

Blower Motor
Blower Motor Speed Control
Connector Circuit Connector
C288-A VH219 (GY) C271-E
C288-B VH301 C271-D
(YE/BU)

S11 CHECK CIRCUITS VH219 (GY) AND VH301
(YE/BU) FOR A SHORT TOGETHER
Yes
• Measure the resistance between blower motor C288-A, GO to S12 .
circuit VH219 (GY), harness side and blower motor
C288-B, circuit VH301 (YE/BU), harness side. No
REPAIR circuits VH219 (GY) and
VH301 (YE/BU) for a short together.

S12 CHECK CIRCUIT VH219 (GY) FOR A SHORT TO
GROUND
Yes
• Measure the resistance between ground and blower GO to S13 .
motor C288-A, circuit VH219 (GY), harness side.
No
REPAIR circuit VH219 (GY) for a
short to ground. TEST the system for
normal operation.

S13 CHECK CIRCUIT VH301 (YE/BU) FOR A SHORT

TO VOLTAGE
Yes
• Ignition ON. REPAIR circuit VH301 (YE/BU) for a
• Measure the voltage between ground and blower motor short to voltage. TEST the system for
C288-B, circuit VH301 (YE/BU), harness side. normal operation.
No
GO to S16 .

S14 CHECK THE RELAY SWITCH POWER CIRCUIT
FOR AN OPEN
Yes
• Measure the voltage between blower motor relay socket GO to S15 .
pin 30, circuit SBB35 (BU/RD) and ground.
No
VERIFY Battery Junction Box (BJB)
fuse 35 (40A) is OK. If OK, REPAIR
circuit SBB35 (BU/RD) for an open.
If not OK, REFER to the Wiring
Diagrams manual to identify the
possible causes of the circuit short.

S15 CHECK THE MODULE OUTPUT
Yes
NOTICE: The following step use a test light to INSTALL a new blower motor relay.
simulate normal circuit loads. Use only the test light TEST the system for normal operation.
recommended in the Special Tools table at the
beginning of this section or equivalent. To avoid No
connector terminal damage, use the Flex Probe kit GO to S17 .
for the test light probe connection to the vehicle. Do
not use the test light probe directly on any connector.
• Ignition ON.
• With the engine running, connect a 12-volt test lamp
between blower motor relay socket pin 85, circuit
CH123 (VT/GN) and socket pin 86, circuit CBP45 (YE).


S16 CHECK THE BLOWER MOTOR SPEED CONTROL
CONNECTION
Yes
• Clear the DTCs. INSTALL a new blower motor speed
• Disconnect the blower motor speed control connector. control. REFER to Section 412-01 .
• Check for: CLEAR the DTCs. TEST the system
• Connect and correctly seat the connector. The system is operating correctly at
• Carry out the HVAC On-Demand Self Test. this time. The concern may have been
present. connector. CLEAR the DTCs. TEST
• Is the concern still present? the system for normal operation.
S17 CHECK THE MODULE CONNECTION
Yes
• Is the concern still present? REPEAT the self-test. TEST the
Pinpoint Test T: The Blower Motor Does Not Operate Correctly â DATC
Normal Operation
speed.

• DTC B10B9:14 (Blower Control: Circuit Short to Ground or Open) â The module senses no
voltage on the blower motor control PWM circuit, indicating an open or a short directly to ground.

• Fuse(s)
• HVAC module â Dual Automatic Temperature Control (DATC)
PINPOINT TEST T: THE BLOWER MOTOR DOES NOT OPERATE CORRECTLY â DATC

T1 CHECK THE HVAC MODULE FOR DTCs
Yes
• Ignition ON. For DTC B10AF:14 , REPAIR circuit CH123
• Check the HVAC module for DTCs. (VT/GN) for a short to ground. CLEAR the
For DTC B10B9:14 , REPAIR circuit VH101

(WH/VT) for a short to ground. CLEAR the
DTCs. REPEAT the self-test. TEST the system
No
GO to T2 .
T2 VERIFY THE BLOWER MOTOR
OPERATION
Yes
• Ignition ON. If the blower motor operates always in HI, GO
• Press the panel button on the HVAC module. to T3 .
Adjust the blower motor setting to LO and then
to HI. If the blower motor is always ON, CARRY
• Does the blower motor operate at any OUT the blower motor relay component test.
setting?
Fusion/MKZ , Fusion Hybrid/MKZ Hybrid )
If the relay tests OK, GO to T5 .
No
GO to Pinpoint Test S .
T3 CHECK CIRCUIT VH301 (YE/BU) FOR A
SHORT TO VOLTAGE
PINPOINT TEST T: THE BLOWER MOTOR DOES NOT OPERATE CORRECTLY â DATC 4912

• Disconnect: Blower Motor Speed Control REPAIR circuit VH301 (YE/BU) for a short to
C271. voltage. TEST the system for normal operation.
• Ignition ON. No
• Measure the voltage between ground and GO to T4 .
blower motor speed control C271-E, circuit
VH301 (YE/BU), harness side.

T4 CHECK CIRCUIT VH219 (GY) FOR A
SHORT TO GROUND
Yes
• Ignition OFF. INSTALL a new blower control. TEST the
• Measure the resistance between ground and system for normal operation. If the condition
blower motor speed control C271-D, circuit returns, GO to T5 .
VH219 (GY), harness side.
No
REPAIR circuit VH219 (GY) for a short to
voltage. TEST the system for normal operation.

T5 CHECK THE MODULE CONNECTION
Yes
• Connect and correctly seat all the HVAC No
module connectors. The system is operating correctly at this time.
• Operate the system and verify the concern is or corroded connector. CLEAR the DTCs.
still present. REPEAT the self-test. TEST the system for
Component Tests
Blower Motor Resistor
Blower Motor Resistor Pins Approx. Resistance

C and B 1.27 ohms
C and A 2.45 ohms
C and D 4.5 ohms
Temperature Sensor â In-Vehicle

-40Â°C (-40Â°F) 869,073-1,061,986 ohms
-15Â°C (5Â°F) 196,465-231,213 ohms
0Â°C (32Â°F) 89,982-102,514 ohms
15Â°C (59Â°F) 44,261-49,503 ohms
25Â°C (77Â°F) 28,500-31,500 ohms
35Â°C (95Â°F) 18,563-20,751 ohms
60Â°C (140Â°F) 6,971-8,001 ohms
85Â°C (185Â°F) 2,959-3,474 ohms
Temperature Sensor â Ambient

-40Â°C (-40Â°F) 832,519-1,017,523 ohms
-15Â°C (5Â°F) 199,325-220,307 ohms
0Â°C (32Â°F) 91,058-100,644 ohms
15Â°C (59Â°F) 44,435-49,113 ohms

25Â°C (77Â°F) 28,500-31,500 ohms
35Â°C (95Â°F) 18,730-20,701 ohms
60Â°C (140Â°F) 7,171-7,925 ohms
85Â°C (185Â°F) 3,110-3,438 ohms
Air Inlet Mode Door Actuator
Actuator Pins Approx. Resistance

51 and 6 71-85 ohms
Defrost/Panel/Floor Door Actuator

8 and 10 8,000-12,000 ohms
8 and 9 1-10,000 ohms
9 and 10 1-10,000 ohms
5 and 6 38-48 ohms
Temperature Blend Door Actuator
8 and 10 8,000-12,000 ohms

8 and 9 1-10,000 ohms
9 and 10 1-10,000 ohms
5 and 6 59-73 ohms

-5Â°C (23Â°F) 111,677-136,089 ohms
0Â°C (32Â°F) 87,028-106,252 ohms
5Â°C (41Â°F) 67,969-82,801 ohms
10Â°C (50Â°F) 53,505-64,741 ohms
15Â°C (59Â°F) 42,389-51,206 ohms
20Â°C (68Â°F) 33,860-40,844 ohms
25Â°C (77Â°F) 27,058-32,942 ohms
30Â°C (86Â°F) 21,443-27,036 ohms
35Â°C (95Â°F) 16,583-22,808 ohms
40Â°C (104Â°F) 12,177-20,007 ohms
Heater Core
1. NOTE: If a heater core leak is suspected, the heater core must be tested by following the Plugged
Heater Core Component Test before the heater core pressure test. Carry out a system inspection by
checking the heater system thoroughly as follows:
Inspect for evidence of coolant leakage at the heater hose to heater core attachments. A coolant leak in
the heater hose could follow the heater core tube to the heater core and appear as a leak in the heater
core.
2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of
non-specified clamps can cause leakage at the heater hose connection and damage the heater core.
Check the integrity of the heater hose clamps.
Heater Core â Plugged
1. Check to see that the engine coolant is at the correct level.
2. Start the engine and turn on the heater.
3. When the engine coolant reaches operating temperature, using a suitable temperature measuring
device, check the core inlet and outlet hoses to see if they are hot.
4. If the outlet only is not hot:

• the heater core may have an air pocket.
• the heater core may be plugged.
5. If the inlet only is not hot:

• the thermostat may not be working correctly.
Heater Core â Pressure Test
WARNING: Before disconnecting any heater water hoses, shut OFF the engine and wait until
engine is fully cool. Failure to comply with this warning may result in serious injury or burns from hot
liquid escaping from the engine cooling system.
Use the Pressure Test Kit to carry out the pressure test.
1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
Drain the coolant from the cooling system.
2. Disconnect the heater hoses from the heater core.
3. Install a short piece of heater hose, approximately 101 mm (4 in) long on each heater core tube.
4. Fill the heater core and heater hoses with water and install the plug BT-7422-B and the adapter
BT-7422-A from the Pressure Test Kit. Secure the heater hoses, plug and adapter with hose clamps.
5. Attach the pump and gauge assembly from the Pressure Test Kit to the adapter.
6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure into the heater
core.
7. Observe the pressure gauge for a minimum of 3 minutes.
8. If the pressure drops, check the heater hose connections to the core tubes for leaks. If the heater hoses
do not leak, remove the heater core from the vehicle and carry out the bench test.
Heater Core â Bench Test
1. Remove the heater core from the vehicle.
2. Drain all of the coolant from the heater core.
3. Connect the 101 mm (4 in) test heater hoses with plug and adapter to the core tubes. Then connect the
Pressure Test Kit to the adapter.
4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water.
5. If a leak is observed, install a new heater core.
Evaporator/Condenser Core â On-Vehicle Leak Test
1. Discharge and recover the refrigerant. Refer to Air Conditioning (A/C) System Recovery, Evacuation
and Charging in this section.
2. Disconnect the suspect evaporator core or condenser core from the A/C system.
3. Clean the manifold fittings.
4. Connect the appropriate test fittings from the A/C Flush Adapter Kit to the condenser or evaporator
core tube connections.
5. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the
test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used,
make sure the valve opens when attached to the test fittings or install an adapter that will activate the
valve. The test is not valid if the shut-off valve does not open.
Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the
evaporator core or condenser core. Connect the yellow hose to a known good vacuum pump.
6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a
minimum of 45 minutes after the gauge set low-pressure gauge indicates 101 kPa (30 in-Hg). The
45-minute evacuation is necessary to remove any refrigerant from oil left in the evaporator core or
condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the
vacuum and appear as a refrigerant leak.
7. If the low-pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge
and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe
the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test
fitting connections and gauge set connections before installing a new evaporator core or condenser
core.
8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the
low-pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark.
• If the low-pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from
the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated.
• If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge.
• If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an
additional 30 minutes to remove any remaining refrigerant from the oil in the evaporator core
or condenser core. Then recheck for loss of vacuum.
• If a very small leak is suspected, allow the system to sit overnight with vacuum applied and
check for vacuum loss.
9. If the evaporator core or condenser core does leak, as verified by the above procedure, install a new
evaporator core or condenser core.
A/C Compressor â External Leak Test
1. Install the appropriate adapter from the A/C Flush Adapter Kit on the port of the A/C compressor,
using the existing manifold retaining bolt.
2. Connect the high- and low-pressure lines of a manifold gauge set or a refrigerant recovery/recycling
station to the corresponding fittings on the adapter.
3. Attach the center hose of a manifold gauge set to a refrigerant container standing in an upright
position.
4. Open the low-pressure gauge valve, the high-pressure gauge valve and the valve on the refrigerant
container to allow the refrigerant vapor to flow into the A/C compressor.
5. Using the Refrigerant Leak Detector, check for leaks at the compressor shaft.
6. If a shaft seal leak is found, install a new compressor shaft seal. If an external leak is found, install a
new A/C compressor.
7. When the leak test is complete, recover the refrigerant from the compressor.
SECTION 412-00A: Climate Control System - General 2012 Fusion, MKZ, Fusion Hybrid, MKZ
Information and Diagnostics Hybrid Workshop Manual
Refrigerant System Tests
Special Tool(s)

R-134a Refrigerant Management Machine

(SAE J2788 Compliant)
(SAE J-2788 Compliant)
Procedure 1 - Ambient Temperature at or Below 38°C (100°F)
NOTE: The system performance can be evaluated and diagnosed by analysis of the compressor suction and
discharge pressures. The following procedure is used to determine if the system is operating at normal
pressures.
NOTE: The procedure varies depending on the ambient (shop) temperature. If the ambient temperature is
38°C (100°F) or lower, follow Procedure 1. If the ambient temperature is over 38°C (100°F), follow
Procedure 2.
NOTE: If the A/C compressor cycles at any time during this test, refer to the diagnostic table.
1. Drive the vehicle or run the engine until it reaches normal operating temperature.
2. Connect a R-134a Manifold Gauge Set or R-134a Refrigerant Management Machine with
high-pressure and low-pressure gauges to the refrigerant system.
3. Set the climate controls.

• If equipped with manual climate control, set the A/C controls for normal A/C-PANEL mode,
full COOL temperature,ir, HI blower. If the vehicle has a fresh air/recirc button, set it to
FRESH. If the vehicle has an A/C switch or compressor on switch, set it to A/C ON.
• If equipped with Electronic Automatic Temperature Control (EATC) or Dual Automatic
Temperature Control (DATC), set temperature to 15°C (60°F) (lowest possible temp setting)
with the dual function disabled (if equipped). Manually set blower on HI. If the vehicle has a
fresh air/recirc button, set it to FRESH. If the vehicle has an A/C switch or compressor on
switch, set it to A/C ON.
4. Open all vehicle windows and leave the hood open for the test. Open the rear doors.
Refrigerant System Tests 4921

5. Confirm the compressor clutch is engaged and the engine cooling fan(s) are operating or engaged.
Allow the vehicle to idle until the suction (low-side) and discharge (high-side) pressures are stable or
fluctuate in a range that repeats.
6. Record the ambient (shop) temperature.
7. Record the discharge pressure. If the pressure is fluctuating, record the average value.
8. Determine if the discharge pressure falls within the normal operating limits using the Normal
Refrigerant Discharge Pressures chart.
9. Record the suction pressure. If the pressure is fluctuating, record the average value.
10. Determine if the suction pressure falls between normal operating limits using the Normal Refrigerant
Suction Pressures chart.
11. Proceed to the Diagnostic Table.
Procedure 2 - Ambient Temperature Above 38°C (100°F)
NOTE: The system performance can be evaluated and diagnosed by analysis of the compressor suction and
discharge pressures. The following procedure is used to determine if the system is operating at normal
pressures.

NOTE: The procedure varies depending on the ambient (shop) temperature. If the ambient temperature is
38°C (100°F) or lower, follow Procedure 1. If the ambient temperature is over 38°C (100°F), follow
Procedure 2.
1. Drive the vehicle or run the engine until it reaches normal operating temperature.
2. Connect a R-134a Manifold Gauge Set or R-134a Refrigerant Management Machine with
high-pressure and low-pressure gauges to the refrigerant system.
3. Set the climate controls.

• If equipped with manual climate control, set the A/C controls for normal A/C-PANEL mode,
full COOL temperature, FRESH air, MED-LO blower. If the vehicle has a fresh air/recirc
button, set it to FRESH. If the vehicle has an A/C switch or compressor on switch, set it to
A/C ON.
• If equipped with Electronic Automatic Temperature Control (EATC) or Dual Automatic
Temperature Control (DATC), set temperature to 15°C (60°F) (lowest possible temp setting).
Manually set blower to MED-LO (3 to 4 bars). If the vehicle has a fresh air/recirc button, set
it to FRESH. If the vehicle has an A/C switch or compressor on switch, set it to A/C ON.
4. Open all vehicle windows the hood open for the test. Open the rear hatch and/or rear doors (if
equipped).
5. Confirm the compressor clutch is engaged and the engine cooling fan(s) are operating or engaged.
Allow the vehicle to idle until the suction (low-side) and discharge (high-side) pressures are stable or
fluctuate in a range that repeats.
6. Record the ambient (shop) temperature.
7. Record the discharge pressure. If the pressure is fluctuating, record the average value.
8. Determine if the discharge pressure falls within the normal operating limits using the Normal
Refrigerant Discharge Pressures chart.
9. Record the suction pressure. If the pressure is fluctuating, record the average value.
10. Determine if the suction pressure falls between normal operating limits using the Normal Refrigerant
Suction Pressures chart.

11. Proceed to the Diagnostic Table.
Diagnostic Table
1. NOTE: The following table is used to guide diagnosis of the refrigerant system if operating pressures
are outside normal limits.
Refer to the chart below.
High Low
(Discharge) (Suction)
Pressure Pressure Component - Causes
High or Clutch High Condenser - inadequate airflow.
Cycling
High Normal to Engine - overheating.
High
Normal to High Normal Refrigerant overcharge - air in refrigerant.
Normal to Low Normal to A/C suction line - partially restricted or plugged. a
High
Normal to Low Low or Low refrigerant charge, A/C suction line - partially restricted or
Clutch plugged A/C evaporator discharge air temperature sensor - reading
Cycling erratic or low (if equipped). b
Erratic Operation or A/C evaporator discharge air temperature sensor - poor connection
Compressor Not Running at A/C clutch connector or A/C evaporator discharge air temperature
sensor connector. A/C electrical circuit erratic - see A/C Electrical
Circuit Wiring Diagram.
Normal to Low High Compressor - low performance.
Additional Possible Cause Components Associated With Inadequate Compressor Operation
Additional Possible Cause Components Associated With a Damaged Compressor
• Incorrect Clutch Air-gap
• Refrigerant Leaks
a Low pressure reading will be normal to high if restriction is downstream of service access valve.
b Low pressure reading will be low if pressure is taken near the compressor and restriction is upstream
of service access valve.


Air Conditioning (A/C) Clutch Air Gap Adjustment
1. Check the A/C clutch air gap at 3 equally spaced places between the clutch plate and the A/C clutch
pulley.
2. If the A/C clutch air gap is out of range, remove the clutch plate. Add or remove spacers between the
clutch plate hub and the compressor shaft until the clearance is within specification.
Air Conditioning (A/C) Clutch Air Gap Adjustment 4926

Fluorescent Dye Leak Detection
Special Tool(s)
Cordless/Rechargable True UV LED Light

ES
R-134a Leak Detection Dye
164-R6060
R-134a Loop/Add On Injector Kit-Set



Fluorescent Dye Injection - Using an R-134a Refrigerant Management Center and Dye/Lubricant
Injector (Non-Hybrid Only)
NOTICE: Do not add liquid-based R-134a Leak Detection Dye to the refrigerant system on hybrid
vehicles equipped with an electric Air Conditioning (A/C) compressor. Liquid-based dyes are mixed
with PAG oil, and will contaminate and damage the hybrid refrigerant system. Dye can only be added
to hybrid vehicles by installing a new received/drier desiccant cartridge which includes a fluorescent
dye "wafer" which will dissolve after approximately 30 minutes of continued A/C operation.
NOTE: Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in
refrigerant system leak diagnosis using a Rotunda-approved UV blacklight. It is not necessary to add
additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has
been removed from the system. Replacement receiver/drier desiccant cartridges are shipped with a fluorescent
dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued
A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new
receiver/drier desiccant cartridge is installed as part of the flushing or filtering procedure. Additional
refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has
been lost due to a fitting separation, hose rupture or other damage.
NOTE: This method of fluorescent dye injection requires the addition of R-134a from a R-134a Refrigerant
Fluorescent Dye Leak Detection 4927

Management Machine or R-134a Manifold Gauge Set hooked to an external tank to charge the dye into the
refrigerant system. If adding fluorescent dye to a refrigert system that is already fully charged, the R-134a
Loop/Add On Injector Kit-Set method should be used.
NOTE: Before using the R-134a Loop/Add On Injector Kit-Set for the first time, refer to the manufacturer's
instructions on evacuation of any non-condensable gases from the hoses.
NOTE: Only connect the dye/lubricant injector from the R-134a Loop/Add On Injector Kit-Set when
fluorescent dye is to be injected. The dye/lubricant injector has a one-way check valve that will prevent
refrigerant system recovery and evacuation.
NOTE: Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the
engine off.
1. NOTE: If no R-134a pressure is present in the refrigerant system, the system should be evacuated
before carrying out the injection procedure. For additional information, refer to Air Conditioning
(A/C) System Recovery, Evacuation and Charging in this section.
Connect a R-134a Refrigerant Center or a R-134a Manifold Gauge Set to the refrigerant system
service port valves.
2. NOTE: The dye/lubricant injector is included as part of the 219-00069 R-134a Loop/Add On Injector
Kit-Set.
Verify that the valves on the dye/lubricant injector are closed.
3. Fill the fluorescent e injector reservoir with 7 ml (0.25 oz) of fluorescent dye.
4. Install the dye/lubricant injector between the low-pressure service gauge port valve and the R-134a
Refrigerant Center or R-134a Manifold Gauge Set.
5. Open all valves and inject the fluorescent dye into the refrigerant system.
6. When fluorescent dye injection is complete, close all valves.
7. Recover the refrigerant from the dye/lubricant injector.
8. Remove the dye/lubricant injector from the low-pressure service gauge port valve and the R-134a
Refrigerant Center or R-134a Manifold Gauge Set.

Fluorescent Dye Injection - Using an R-134a Loop/Add On Injector Kit-Set (Non-Hybrid Only)
NOTICE: Do not add liquid-based R-134a Leak Detection Dye to the refrigerant system on hybrid
vehicles equipped with an electric Air Conditioning (A/C) compressor. Liquid-based dyes are mixed
with PAG oil, and will contaminate and damage the hybrid refrigerant system. Dye can only be added
to hybrid vehicles by installing a new received/drier desiccant cartridge which includes a fluorescent
dye "wafer" which will dissolve after approximately 30 minutes of continued A/C operation.
NOTE: Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in
refrigerant system leak diagnosis using a Rotunda-approved UV blacklight. It is not necessary to add
additional dye to the refrigerant system before diagnosing leaks, even if a signicant amount of refrigerant has
been removed from the system. Replacement receiver/drier desiccant cartridges are shipped with a fluorescent
dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued
A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new
receiver/drier desiccant cartridge is installed as part of the flushing or filtering procedure. Additional
refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has
been lost due to a fitting separation, hose rupture or other damage.
NOTE: Before using the R-134a Loop/Add On Injector Kit-Set for the first time, refer to the equipment
manufacturer's instructions on evacuation of non-condensable gases from the hoses.
NOTE: Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the
engine off and cool.
1. Verify that the valves on the deluxe injector loop kit are closed.
2. Fill the R-134a Loop/Add On Injector Kit-Set reservoir with 7 ml (0.25 oz) of fluorescent dye.
3. Install the R-134a Loop/Add On Injector Kit-Set between the high-pressure and low-pressure service
gauge po valves.
4. NOTICE: Make sure all tools and hoses are clear of the engine cooling fan and drive belt before
starting the engine.
Start the engine.
5. Set the A/C to the ON position.

6. Open the high-pressure service valve.
7. NOTE: To prevent pressure spike/liquid slug, crack the R-134a Loop/Add On Injector Kit-Set valves
and slowly open to inject the fluorescent dye into the refrigerant system.
Open the R-134a Loop/Add On Injector Kit-Set valves and inject the fluorescent dye into the
refrigerant system.
8. Close the high-pressure service valve to allow the pressure inside the R-134a Loop/Add On Injector
Kit-Set to equalize with the suction side of the refrigerant system.
9. NOTE: Close the valves on the R-134a Loop/Add On Injector Kit-Set while the A/C compressor is
operating.
Close the valves on the R-134a Loop/Add On Injector Kit-Set.
10. NOTE: Leave all valves on the R-134a Loop/Add On Injector Kit-Set closed when not in use.
Disconnect the high-pressure and low-pressure service valves and remove the R-134a Loop/Add On
Injector Kit-Set from the vehicle.
Fluorescent Dye Detection

NOTE: Ford Motor Company vehicles are produced with R-134a fluorescent dye installed in the refrigerant
system from the factory. The location of leaks can be pinpointed by the bright yellow-green glow of the
fluorescent dye under a UV lamp. Since more than one leak can exist, make sure to inspect each component,
line and fitting in the refrigerant system for a leak.
1. Check for leaks using a Rotunda-approved UV lamp.

• Inspect all components, lines and fittings of the refrigerant system.
2. If a leak is found, recover the refrigerant. For additional information, refer to Air Conditioning (A/C)
System Recovery, Evacuation and Charging in this section.
3. Repair the refrigerant system leak(s).
4. Evacuate and charge the refrigerant system. For additional information, refer to Air Conditioning
5. After the leak(s) is repaired, remove any traces of fluorescent dye with a general purpose oil solvent.
6. Verify the repair by running the vehicle for a short period of time and rechecking the area of the leak
with a Rotunda-approved UV lamp.

Electronic Leak Detection
Special Tool(s)
Heated Pentode Halogen Leak Detector

NOTE: Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If the
surrounding air is contaminated with refrigerant gas, the Heated Pentode Halogen Leak Detector will indicate
this gas all the time. Odors from other chemicals such as antifreeze, diesel fuel, disc brake cleaner or other
cleaning solvents can cause the same problem. Using a fan to ventilate the area to be tested before proceeding
with the leak detection procedure is helpful in removing small traces of contamination from the air, but the fan
should be turned off during actual testing.
NOTE: R-134a is heavier than air, and will tend to move downward from the source of the leak if present. It
is possible that a leak may not be detected if the leak detector tip is held above the leaking fitting, line or
component. Always be sure to thoroughly leak test below the fitting, line or component for the presence of
R-134a as well as leak testing above and around.
1. NOTE: The system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the
engine off and cool. The pressure reading may be higher if the engine is hot.
Leak test the refrigerant system using the Heated Pentode Halogen Leak Detector. Follow the
instructions included with the Heated Pentode Halogen Leak Detector for handling and operation
techniques.
Electronic Leak Detection 4932

Electronic Leak Detection 4933

Air Conditioning (A/C) System Recovery, Evacuation and Charging
Special Tool(s)
6.0 CFM Vacuum Pump

300-R0B15600E or equivalent
Automatic Refrigerant Charging Meter



300-R0B34788-PROE or equivalent
Material
Item Specification
Compressor Oil
YN-32
PAG Refrigerant Compressor Oil WSH-M1C231-B
(R-134a Systems)
YN-12-D
R-134a Refrigerant WSH-M17B19-A
YN-19 (US); CYN-16-P or
CYN-16-R (Canada)
Refrigerant System Recovery
NOTICE: Motorcraft® Electric A/C Compressor Oil only must be used as a refrigerant system
lubricant for hybrid vehicles. Addition of any oil other than Motorcraft® Electric A/C Compressor Oil
to the hybrid vehicle refrigerant system will damage the electric Air Conditioning (A/C) compressor
and contaminate the refrigerant system. For additinal information, refer to Refrigerant Oil Adding in
this section.
NOTICE: Do not use the R-134a Refrigerant Management Machine built-in oil injection system to
inject Motorcraft Electric A/C Compressor Oil to the refrigerant system on hybrid vehicles equipped
Air Conditioning (A/C) System Recovery, Evacuation and Charging 4934

with an electric Air Conditioning (A/C) compressor if it has been previously used to inject PAG oil. For
hybrid vehicles, use only clean manual injection tools. Injection of Motorcraft Electric A/C Compressor
Oil into a hybrid vehicle with equipment previously used with PAG oil will contaminate and damage
the hybrid A/C system.
NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of any
vehicle's A/C refrigerant. Failure to do so puts the shop's refrigerant at risk of contamination. If the
vehicle's A/C refrigerant is contaminated, refer the customer to the service facility that carried out the
last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery equipment that
is designated for recovering contaminated A/C refrigerant. All contaminated A/C refrigerant must be
disposed of as hazardous waste. For all equipment, follow the equipment manufacturer procedures and
instructions.
NOTE: Ford Motor Company recommends the use of R-134a refrigerant management equipment that meets
the requirements of the SAE J2788 standard.
NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out
recovery. If a R-134a Refrigerant Management Machine is not available, refrigerant system recovery may be
accomplished using a separate recovery station.
NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may
be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant
system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present.
1. Prior to recovering, the purity of the refrigerant must be verified. For additional information, refer to
Refrigerant Identification Testing in this section.
2. Connect a R-134a Refrigerant Management Machine to the low- and high-pressure service gauge port
valves following the operating instructions provided by the equipment manufacturer.
3. Recover the refrigerant from the system following the operating instructions provided by the
equipment manufacturer. Note the amount of oil removed during the refrigerant recovery (if any).
Add that same amount back into the system once repairs are complete.
4. Once the R-134a Refrigerant Management Machine has recovered the refrigerant, switch OFF the
power supply.
5. Allow the system to set for about 2 minutes, and observe the system vacuum reading. If the vacuum is
not lost, disconnect the recovery equipment.
6. If the system does lose vacuum, repeat Steps 3 through 5 until the vacuum level remains stable for 2
minutes.
7. Carry out the required repairs.
Refrigerant System Evacuation Using a R-134a Refrigerant Management Machine
and contaminate the refrigerant system. For additional information, refer to Refrigerant Oil Adding in
this section.

Oiinto a hybrid vehicle with equipment previously used with PAG oil will contaminate and damage the
hybrid A/C system.
recovery, evacuation and charging of the refrigerant system. If a R-134a Refrigerant Management Machine is
not available, evacuation may be accomplished using a separate Vacuum Pump and R-134a Manifold Gauge
Set.
1. Connect a R-134a Refrigerant Management Machine to the low- and high-pressure service gauge port
2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and
as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the Vacuum Pump for a minimum of
45 minutes.
3. Turn OFF the Vacuum Pump. Observe the low-pressure gauge for 5 minutes to make sure that the
system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and
evacuate the system again.
Refrigerant System Evacuation Using a R-134a Manifold Gauge Set and Vacuum Pump
and contaminate the refrigerant system. For additional information, refer to Refrigerant Oil Adding in
this section.
evacuation of the refrigerant system. If a R-134a Refrigerant Management Machine is not available,
refrigerant system evacuation may be accomplished using a separate Vacuum Pump and R-134a Manifold
Gauge Set.
1. Connect the R-134a Manifold Gauge Set to the low-side and high-side service gauge port valves.
2. Connect the center (yellow) hose from the R-134a Manifold Gauge Set to the suction port on the
Vacuum Pump.
3. Open all valves on the R-134a Manifold Gauge Set and both service gauge port valves.
4. Turn on the Vacuum Pump and evacuate the system until the low-pressure gauge reads at least 99.4
kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the

Vacuum Pump for a minimum of 45 minutes.
5. Close the high-side and low-side valves on the R-134a Manifold Gauge Set (not the service gauge
port valves) and turn OFF the Vacuum Pump.
6. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If vacuum
is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again.
Refrigerant System Charging Using a R-134a Refrigerant Management Machine
charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, refrigerant
system charging may be accomplished using a separate Automatic Refrigerant Charging Meter and R-134a
Manifold Gauge Set.
NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be
misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant
1. NOTICE: Motorcraft® Electric A/C Compressor Oil only must be used as a refrigerant system
lubricant for hybrid vehicles. Addition of any oil other than Motorcraft® Electric A/C
Compressor Oil to the hybrid vehicle refrigerant system will damage the electric Air
Conditioning (A/C) compressor and contaminate the refrigerant system. For additional
information, refer to Refrigerant Oil Adding in this section.
NOTICE: Do not use the R-134a Refrigerant Management Machine built-in oil injection system
to inject Motorcraft Electric A/C Compressor Oil to the refrigerant system on hybrid vehicles
equipped with an electric Air Conditioning (A/C) compressor if it has been previously used to
inject PAG oil. For hybrid vehicles, use only clean manual injection tools. Injection of
Motorcraft Electric A/C Compressor Oil into a hybrid hicle with equipment previously used
with PAG oil will contaminate and damage the hybrid A/C system.
Lubricate the refrigerant system with the correct amount of clean PAG oil (non-hybrid vehicles) or
electric A/C compressor oil (hybrid vehicles). For additional information, refer to Refrigerant Oil
Adding in this section.
2. Connect a R-134a Refrigerant Management Machine to the low-side and high-side service gauge port
3. Set the refrigerant charge amount, and charge the refrigerant system following the instructions
provided by the equipment manufacturer.
Refrigerant System Charging Using a R-134a Manifold Gauge Set and Automatic Refrigerant
Charging Meter
charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, refrigerant
system charging may be accomplished using a separate Automatic Refrigerant Charging Meter and R-134a
Manifold Gauge Set.
NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be
misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant

lubricant for hybrid vehicles. Addition o any oil other than Motorcraft® Electric A/C
Conditioning (A/C) compressor and contaminate the refrigerant system. For additional
information, refer to Refrigerant Oil Adding in this section.
Lubricate the refrigerant system with the correct amount of clean PAG oil (non-hybrid vehicles) or
2. Assemble the R-134a Manifold Gauge Set, Automatic Refrigerant Charging Meter and R-134a supply
tank following the Automatic Refrigerant Charging Meter operating instructions.
3. Charge the refrigerant system following the Automatic Refrigerant Charging Meter operating
instructions.
4. If the refrigerant flow stops before the refrigerant charge is complete, start the engine, select MAX
A/C operation and allow the refrigerant charge to complete.

Air Conditioning (A/C) System Flushing
Special Tool(s)

A/C Flush and Purge Fitting Kit

A/C Flush and Purge Machine

219-00022 (part of 219-00023) or
equivalent
Material
Item Specification
A/C System Flushing Solvent -
YN-23
Compressor Oil
YN-32
(R-134a Systems)
YN-12-D
WARNING: Take the following precautions when repairing an air conditioning system containing
R-134a:
♦ Always wear safety goggles.

♦ Avoid contact with liquid refrigerant R-134a. R-134a vaporizes at approximately -25°C (-13°F) under
atmospheric pressure and will freeze skin tissue.
♦ Never allow refrigerant R-134a gas to escape in quantity in an occupied space. It will displace the
oxygen needed to support life.
♦ Never use a torch in an atmosphere containing R-134a gas. R-134a is non-toxic at all normal
conditions, but it decomposes when exposed to high temperatures such as a torch flame. During
decomposition it releases irritating and toxic gasses (as described in the MSDS sheet from the
manufacturer). Decomposition products are hydrofluoric acid, carbon dioxide and water. ul>Failure to
follow these instructions may result in serious personal injury.
Conditioning (A/C) compressor and contaminate the refrigerant system. Refer to Refrigerant
Oil Adding in this section.
Air Conditioning (A/C) System Flushing 4939

NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of
any vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of
contamination. If the vehicle's A/C refrigerant is contaminated, refer the customer to the
service facility that carried out the last A/C service. If the customer wishes to pay the additional
cost, use the A/C recovery equipment that is designated for recovering contaminated A/C
refrigerant. All contaminated A/C refrigerant must be disposed of as hazardous waste. For all
equipment, follow the equipment manufacturer procedures and instructions.
NOTICE: Receiver/drier cartridge, Thermostatic Expansion Valve (TXV), and hoses with
mufflers should be removed when flushing the Air Conditioning (A/C) system. Internal
plumbing of these devices makes it impossible to correctly remove any residual-flushing agent.
These components are typically discarded after A/C system contamination. Hoses without
mufflers can normally be reused unless they are clogged with foreign material. The 3.785L (1
gal) of A/C System Flushing Solvent YN-23 and FL1-A filter used in A/C Flush and Purge
Machine 219-00022 are intended fouse on one vehicle only. They may be used to flush both the
A/C condenser core and the A/C evaporator core on an individual vehicle, but under no
circumstances should they be used on more than one vehicle.
NOTICE: Only the A/C Flush and Purge Machine 219-00022 and A/C Systems Flushing
Solvent, is approved for use on Ford vehicles. No other flushing device or solvent is approved
for flushing heat exchangers (Air Conditioning [A/C] condenser, A/C evaporator). Use of any
other flusher or solvent may cause damage to the A/C system and the flushing unit.
NOTE: Prior to using the A/C Flush and Purge Machine 219-00022 for the first time, review the
operating instructions.
NOTE: Ford Motor Company has approved a procedure to provide technicians with a non-CFC
method of flushing contaminated A/C system heat exchangers. The procedure allows the specific
components to be cleaned and flushed while installed in their normal in-vehicle location. The types of
contamination flushed include particle matter that results from A/C compressor or desiccant failure
and gummy residue that can form when refrigerant oil is overheated during A/C compressor seizure.
The flushing process is a 2-step procedure that involves the use of an A/C Flush and Purge Machine
219-00022 to:
• circulate the flushing solvent through the heat exchanger in the reverse direction of normal
refrigerant flow (back-flushing). Particulate matter picked up during flushing is filtered from
the returning solvent before the solvent is returned to the reservoir for continued circulation.
• remove the flushing solvent from the heat exchanger. In this step of the procedure,
pressurized air 621-862 kPa (90-125 psi) is used to push and evaporate any remaining flush
solvent from the heat exchanger.
1. Remove the receiver/drier cartridge. For additional information, refer to Section 412-01 .
2. NOTE: The condenser core must be flushed with the receiver/drier cartridge removed. Do
not install a new receiver/drier cartridge at this time.
With the receiver/drier cartridge removed, reinstall the receiver/drier plug and snap ring into
the condenser core.
3. Remove the condenser inlet and outlet fitting nuts and disconnect the fittings.
4. Connect the A/C Flush and Purge Machine to the condenser inlet and outlet fittings using the
correct adapters from the A/C Flush Adapter Kit.
5. Flush the condenser core for a minimum of 30 minutes.
6. Turn the A/C Flush and Purge machine to the PURGE mode and run for a minimum of 20
minutes.
7. Disconnect the A/C Flush and Purge machine and adapters from the condenser core.
8. Install new gasket seals and connect the A/C condenser inlet and outlet fittings.

9. Remove the snap ring and receiver/drier plug.
10. NOTE: Do not charge the refrigerant system after the condenser core is installed.
Install a new receiver/drier cartridge. For additional information, refer to Section 412-01 .
11. Remove the Thermostatic Expansion Valve (TXV). For additional information, refer to
Section 412-00A .
12. Connect the A/C Flush and Purge Machine to the evaporator core fitting using the correct
adapter from the A/C Flush and Purge Fitting Kit.
13. Flush the evaporator core for a minimum of 20 minutes.
14. Turn the A/C Flush and Purge Machine to the PURGE mode and run for a minimum of 20
minutes.
15. Disconnect the A/C Flush and Purge Machine and adapter from the evaporator core fitting.
16. Install a new front TXV . For additional information, refer to Section 412-01 .
17. NOTE: It is necessary to evacuate the refrigerant system for a minimum of one hour to
evaporate any traces of flush solvent that may remain in the system.
Evacuate the refrigerant system for one hour. For additional information, refer to Air
Conditioning (A/C) System Recovery, Evacuation and Charging in this section.
18. NOTICE: Motorcraft® Electric A/C Compressor Oil only must be used as a refrigerant
system lubricant for hybrid vehicles. Addition of any oil other than Motorcraft®
Electric A/C Compressor Oil to the hybrid vehicle refrigerant system will damage the
electric Air Conditioning (A/C) compressor and contaminate the refrigerant system.
Refer to Refrigerant Oil Adding in this section.
If a new A/C compressor is not to be installed, lubricate the refrigerant system with the
correct amount of clean PAG oil (non-hybrid vehicles) or electric A/C compressor oil (hybrid
vehicles). For additional information, refer to Refrigerant Oil Adding in this section.
19. If a new A/C compressor is not to be installed, evacuate, leak test and charge the refrigerant
system. For additional information, refer to Air Conditioning (A/C) System Recovery,
Evacuation and Charging in this section.
bsp;

Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation
Special Tool(s)

A/C Flush and Purge Fitting Kit

219-00024 or equent
Material
Item Specification
Compressor Oil
YN-32
(R-134a Systems)
YN-12-D
and contaminate the refrigerant system. Refer to Refrigerant Oil Adding in this section.
NOTICE: On vehicles being serviced for an internal compressor or desiccant failure, a new
Thermostatic Expansion Valve (TXV) and any hoses containing mufflers must be installed prior to
filtering the Air Conditioning (A/C) system. Internal plumbing of these devices makes it impossible to
correctly remove any foreign material/debris. These components are typically discarded after A/C
system contamination. Hoses without mufflers can normally be reused unless they are clogged with
foreign material. The F8VZ-19E773-AB filter is intended for use on one vehicle only.
All vehicles
1. Remove the receiver/drier cartridge. For additional information, refer to Section 412-01 .
2. NOTE: The refrigerant system must be filtered with the receiver/drier cartridge removed. Do not
install a new receiver/drier cartridge at this time.
With the receiver/drier cartridge removed, reinstall the receiver/drier plug and snap ring into the
condenser core.
3. Remove the condenser outlet fitting nut and disconnect the fitting.
• Discard the gasket seal.
4. NOTICE: The flexible extension adapters included in the A/C Flush Adapter Kit (219-00074)
are designed for low-pressure flushing and are not designed for use with a charged refrigerant
Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation 4942
system. Do not make the condenser fitting connections using the flexible extension adapters or
damage to the adapters and loss of refrigerant will occur.
NOTE: Use flexible refrigerant hose of 17,238 kPa (2,500 psi) burst rating.
Using the correct adapters and service hoses, install the pancake filter between the condenser and the
condenser outlet fitting.
Conditioning (A/C) compressor and contaminate the refrigerant system. Refer to Refrigerant
Oil Adding in this section.
Lubricate the refrigerant systemith the correct amount of clean PAG oil (non-hybrid vehicles) or
6. Evacuate and charge the refrigerant system. For additional information, refer to Air Conditioning
Non-hybrid vehicles
7. Provide adequate airflow to the front of the vehicle (with a fan, if necessary). Start the engine and
allow it to idle briefly. Select A/C operation and set the blower speed to HI. Verify that the A/C is
operating correctly.
8. Gradually bring the engine up to 1,200 rpm by running it at lower rpms for short periods (first at 800
rpm, then at 1,000 rpm). Set the engine at 1,200 rpm and run it for one hour with the A/C system
operating.
9. Stop the engine.
Hybrid vehicles
10. Start the vehicle and select A/C operation. Verify that the A/C is operating correctly.
11. Run the A/C system for one hour.
All vehicles
12. Recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System
Recovery, Evacuation and Charging in this section.
13. Remove the pancake filter, hoses and adapters from the vehicle.
14. Install a new gasket seal and connect the condenser outlet fitting.
15. Remove and discard the receiver/drier plug snap ring and the receiver/drier plug.
16. Install a new receiver/drier cartridge. For additional information, refer to Section 412-01 .
17. Evacuate, leak test and charge the refrigerant system. For additional information refer to Air
Refrigerant Oil Adding
Special Tool(s)
R-134a Loop/Add On Injector Kit-Set

Material
Item Specification
Compressor Oil
YN-32
(R-134a Systems)
YN-12-D
Refrigerant Oil Adding
NOTICE: Motorcraft® Electric A/C Compressor Oil only used as a refrigerant system lubricant for
hybrid vehicles. Addition of any oil other than Motorcraft® Electric A/C Compressor Oil to the hybrid
vehicle refrigerant system will damage the electric Air Conditioning (A/C) compressor and contaminate
the refrigerant system.
Oil into a hybrid vehicle with equipment previously used with PAG oil will contaminate and damage
the hybrid A/C system.
NOTICE: During normal Air Conditioning (A/C) operation, oil is circulated through the system with
the refrigerant, and a small amount is retained in each component. If certain components of the system
are removed, some of the refrigerant oil will go with the component. To maintain the original total oil
charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part.
1. Refer to the chart below for refrigerant oil adding amounts and methods of installation.
Component Oil Amount Method of Adding

A/C Compressor - Refer to Adding Refrigerant Oil After Add directly to A/C compressor
Non-Hybrid A/C Compressor Replacement - before installation
Non-Hybrid
Electric A/C Refer to Adding Refrigerant Oil After Inject to low-side service port during
Compressor - Hybrid A/C Compressocement - Hybrid system charging
Receiver/Drier 60 ml (2 fl oz) added to the amount Inject to low-side service port during
Desiccant Cartridge collected during refrigerant recovery system charging
Refrigerant Oil Adding 4945

Evaporator Core 45 ml (1.5 fl oz) added to the amount Add directly to evaporator core inlet
collected during refrigerant recovery tube or inject to low-side service port
during system charging
Condenser Core 60 ml (2 fl oz) added to the amount Add directly to condenser core inlet or
collected during refrigerant recovery inject to low-side service port during
system charging
Thermostatic The amount collected during Inject to low-side service port during
Expansion Valve refrigerant recovery system charging
(TXV)
A/C Pressure Relief 60 ml (2 fl oz) added to the amount Inject to low-side service port during
Valve collected during refrigerant recovery system charging
Refrigerant 60 ml (2 fl oz) added to the amount Inject to low-side service port during
Hose/Line collected during refrigerant recovery a system charging
O-ring Leak Repair 60 ml (2 fl oz) added to the amount Inject to lowide service port during
collected during refrigerant recovery b system charging
Service Port Leak 60 ml (2 fl oz) added to the amount Inject to low-side service port during
Repair collected during refrigerant recovery system charging
a If an excessive amount of refrigerant oil is lost due to a hose rupture/separation or other damage, the
total system refrigerant oil capacity must be added.

b The amount specified may be used for one or multiple O-ring leak repairs. Do not multiply the
refrigerant oil amount by the number of O-ring leaks being repaired.
Adding Refrigerant Oil After A/C Compressor Replacement - Non-Hybrid
NOTE: Service A/C compressors are shipped without refrigerant oil.
1. Rotate the old A/C compressor shaft 8 to 10 full rotations (clockwise) while collecting the PAG oil in
a clean measuring cup.
• Add the same amount plus the amount collected during refrigerant recovery.
Adding Refrigerant Oil After Electric A/C Compressor Replacement - Hybrid
and contaminate the refrigerant system.
hybrid vehicles, us clean manual injection tools. Injection of Motorcraft Electric A/C Compressor Oil
into a hybrid vehicle with equipment previously used with PAG oil will contaminate and damage the
hybrid A/C system.
NOTE: Service electric A/C compressors are shipped with 60 ml (2 fl oz) of electric A/C compressor oil
already installed.
1. Drain the oil from the old electric compressor into a clean measuring cup.
• If the amount of oil drained is less than or equal to 60 ml (2 fl oz), add the amount of oil
collected by the R-134a Refrigerant Management Machine during refrigerant recovery to the
low-side service port after the new electric A/C compressor is installed and the system has

been evacuated.
• If the amount of oil drained is greater than 60 ml (2 fl oz), add the difference between the
amount collected and 60 ml (2 fl oz), plus the amount collected by the R-134a Refrigerant
Management Machine during refrigerant recovery, to the low-side service port after the new
electric A/C compressor is installed and the system has been evacuated.
Oil Injection Using a Dye/Lubricant Injector
and contaminate the refrigerant system.
NOTICE: Do not add liquid based R-134a Leak Detection Dye to the refrigerant system on hybrid
vehicles equipped with an electric A/C compressor. Liquid based dyes are mixed with PAG oil, and will
contaminate and damage the hybrid refrigerant system. Dye can only be added to hybrid vehicles by
installing a new received/drier desiccant cartridge which includes a fluorescent dye "wafer" which ll
dissolve after approximately 30 minutes of continued A/C operation.
NOTE: The dye/lubricant injector is included as part of the 219-00069 R-134a Loop/Add On Injector Kit-Set.
NOTE: If fluorescent leak detection dye is also to be added during A/C charging, the dye may be added to the
dye/lubricant injector along with the refrigerant oil.
1. Evacuate the refrigerant system. For additional information, refer to Air Conditioning (A/C) System
Recovery, Evacuation and Charging in this section.
2. Assemble the dye/lubricant injector using the correct adapters to match the amount of refrigerant
compressor oil to be injected.
3. Verify that all the valves on the dye/lubricant injector are closed.
4. Fill the dye/lubricant injector with the correct amount of new refrigerant compressor oil.
5. Install the dye/lubricant injector between the low-side service gauge port valve and the refrigerant
service station or manifold gauge set.
6. Open all valves and charge the refrigerant system. For additional information, refer to Air



Air Conditioning (A/C) Odor Treatment
Special Tool(s)
Flexible Applicator Tool

258-00005
Material
Item Specification
Motorcraft® A/C Cooling Coil Coating -
YN-29
WARNING: Carry out this procedure in a well-ventilated area with all vehicle windows and doors
opened. Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION, seek medical advice. On Ford/Motorcraft products in the USA or Canada call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS), if
available. Failure to follow these instructions may result in serious personal injury.
NOTE: There are typically 4 types of objectionable odors found in a vehicle:
• Chemical odors
• Environmental odors
• Human and other interior-generated odors
• Microbiological odors
Before determining that A/C odor treatment is required, the sourcnd the circumstances under which the odor
occurs must be determined.
NOTE: Chemical odors are usually constant regardless of the climate control system setting although they
may be enhanced by A/C operation. Most chemical odors are caused by fluid leaks or incorrectly cured
adhesives. Chemical odors can be eliminated by repairing the leaking component and removing any residue.
NOTE: Environmental odors usually occur for a short time and diminish after the vehicle passes through the
affected area. These odors are typically only detected when the vehicle windows are open, or when the
climate control system is operating in a mode that allows for fresh air. Environmental odors cannot be
eliminated because they are external in source, but they may be minimized by switching to a climate control
setting that uses recirculated air.
NOTE: Human and other interior-generated odors occur while the source is present and may linger for a short
time after. These odors may be more noticeable during A/C operation. Human odors may be eliminated by
removing the source and cleaning the affected area.
NOTE: Microbiological odors, if in the A/C system, usually last for about 30 seconds after the system is
turned on. They will be detected while the A/C is turned on and using either outside or recirculated air.
Microbiological odors that occur in areas other than the A/C system (for example, water in doors or wet
carpeting) may last indefinitely and will be more intense when recirculated air is used. Microbiological odors
Air Conditioning (A/C) Odor Treatment 4950

will not be present at temperatures at or below 10°C (50°F).
Microbiological odors can be eliminated by removing the source and treating the affected area. Standing water
must be allowed to drain and dry out. A/C systems may be treated by using A/C cooling coil coating as
described in the service procedure below.
Microbiological odors result from microbial growth supported by warm temperatures and moisture.
Microbiolocal odors are described as musty/mildew type smells and may occur on/in:
• foam seals
• rubber seals
• adhesives
• standing water
• water soaked carpet/trim
1. Identify the type of odor present in the vehicle. Do not proceed with A/C odor treatment if the odor
source is found to be outside of the A/C system. Refer to the following chart for examples.
Odor Source Odor Description

Chemical Odors
Coolant Sweet smell
Fuel Gasoline or diesel fuel smell
Oil Oil type or burning smell
Power Steering Fluid Oil type or burning smell
Transmission Fluid Oil type or burning smell
Washer Fluid Alcohol type smell
Gear Lube Garlic/sulfur smell
Refrigerant Oil Ether type smell
Carpet/trim Adhesives Fishy, urine or sweet smell
Evaporator Core Coating Wet cement type smell
Environmental Odors
Exhaust Exhaust, fuel or burning type smell
Industrial Pollutants Various smells
Dust Musty, mildew or wet cement type smell
Pollen Sweet smell
Tobacco Burning, tar smell
Human and Other Interior Generated Odors
Body Secretions Body odor
Perfuming Agents Sweet or fragrance smell
Clothing Musty, mildew or body odors
Food/Beverage Sweet, musty, mildew or fishy smell
Microbiological Odors
Microbiological Odors Occurring Musty, mildew smell lasting about 30 seconds after A/C is
Inside of A/C System turned on
Microbiological Odors Occurring Musty, mildew smell lasting indefinitely and possibly more
Outside of A/C System pronounced when using recirculated air

2. Identify the source of the odor.

• Check the evaporator core drain tube for restriction.
• Check the passenger and driver side carpet for moisture. If moisture is found, A/C odor
treatment is not necessary. Diagnose for a water leak as needed.
• Check the blower motor and blower motor cover (if equipped) for moisture resulting from
water bypassing the cowl baffling system. If moisture is found, A/C odor treatment is not
necessary. Diagnose for a water leak as needed.
• Check the cowl top panel and air inlet screen for standing water or foreign material. If
possible, remove any standing water and clean the air inlet screen using a wet/dry vacuum.
3. Open all vehicle windows and doors.
4. Make sure that the A/C is off.
5. Set the following.

• Select PANEL mode (A/C off).
• Adjust the temperature setting to full warm.
• Adjust the blower motor speed to HI.
6. Run the engine for 25 minutes to dry out the A/C system.
7. Turn the ignition OFF.
8. Remove the blower motor.
9. NOTE: Blower motor speed controls that are mounted outside of the evaporator core housing and not
exposed to the blower motor airflow do not need to be removed.
Remove the blower motor resistor (if equipped) or blower motor speed control (if equipped and
exposed to the inside of the evaporator core housing).
10. NOTICE: To avoid damage to the vehicle interior, do not spill or spray this product on any
interior surface.
Add one full bottle of A/C cooling coil coating to the Flexible Applicator Tool.
11. Insert the nozzle into the evaporator housing and direct the spray toward the evaporator core face.
Spray the entire evaporator core face until empty.
12. Install the blower motor and blower motor resistor (if equipped) or blower motor speed control (if
equipped).
13. Repeat Steps 4 through 6 to cure the evaporator core coating.


SECTION 412-00B: Climate Control System - General 2012 Fusion, MKZ, Fusion Hybrid, MKZ
Information and Diagnostics - Hybrid Hybrid Workshop Manual
Item Specification
A/C Compressor Oil
NOTICE: Use of any Air Conditioning (A/C)
compressor oil other than what is specified for the
specific vehicle configuration will damage the A/C
compressor and contaminate the refrigerant
system. For non-hybrid vehicles with a pulley
driven (conventional) A/C compressor, PAG
Refrigerant Compressor Oil only must be used.
For hybrid vehicles with an electric A/C
compressor, Motorcraft® Electric A/C
Compressor Oil must be used.
A/C Pressure Relief Valve a
Close pressure 3,103 kPa (450 psi)
Open pressure 3,792-4,137 kPa
(550-600 psi)
aManifold gauge set pressures may vary slightly depending on the distance between the service gauge port
valve and the A/C pressure relief valve, the A/C cycling switch or the pressure cutoff switch location.
NOTE: The specifications apply to hybrid vehicles only. For non-hybrid specifications, refer to Section
412-00A .
Material
Item Specification
Fill Capacity
Motorcraft® Electric A/C - Hybrid vehicles
Compressor Oil only
YN-32 130 ml
(4.4 fl oz)
Motorcraft® R-134a WSH-M17B19-A 0.62 kg
Refrigerant (22 oz)
YN-19 (US); CYN-16-R (1.38 lb)
(Canada)


SECTION 412-00B: Climate Control System - General 2012 Fusion, MKZ, Fusion Hybrid, MKZ
Information and Diagnostics - Hybrid Hybrid Workshop Manual
The system consists of the following components:
• Air Conditioning Compressor Module (ACCM)

• Receiver/drier
• Heater core and evaporator core housing
• HVAC module
• Front Controls Interface Module (FCIM) (all vehicles equipped with navigation systems)
• Temperature blend door actuators
• Blower motor
• In-vehicle temperature/humidity sensor
• Sunload sensor
Humidity Sensor
The humidity sensed by the HVAC module to optimize the Air Conditioning Compressor Module (ACCM)
operation for reduced electrical system load while maintaining passenger comfort.
When the relative humidity inside the vehicle is low, passengers are comfortable at a higher air temperature.
The ACCM can decrease the compressor rpm before the commanded temperature is reached to reduce
compressor electrical load while maintaining passenger comfort.
Hybrid Climate Control System Operation
When an A/C request is made by the HVAC module, a message is sent from the HVAC module over the
Medium Speed Controller Area Network (MS-CAN) bus to the Instrument Cluster (IC), then from the IC
through the High Speed Controller Area Network (HS-CAN) bus to the PCM.

When an A/C request is received from the HVAC module, an A/C demand message is sent from the PCM
over the HS-CAN bus to the Air Conditioning Compressor Module (ACCM) if all of the following conditions
are met:
transducer.
• The PCM does not detect an ambient air temperature below -1°C (30°F).
• The HVAC module does not detect an evaporator discharge air temperature below 2°C (36°F).
When the ACCM receives the A/C demand message, it will engage. Instead of cycling ON and OFF like a
traditional A/C compressor, the PCM monitors the evaporator discharge temperature from the HVAC module
to raise or lower the electric A/C compressor speed as required. When the HVAC module is OFF or not
requiring A/C operation, the electric A/C compressor will be OFF.
Auxiliary Coolant Flow Pump
An auxiliary coolant flow pump is used only on hybrid vehicles to improve engine coolant circulation, for
heater operation, at low engine speeds or when the engine is OFF.
For a complete explanation of the auxiliary coolant flow pump refer to heating and ventilation in the
Description and Operation portion of Section 412-01 .
p;

SECTION 412-00B: Climate Control System - General 2012 Fusion, MKZ, Fusion Hybrid,
Information and Diagnostics - Hybrid MKZ Hybrid Workshop Manual
Special Tool(s)
Flex Probe Kit


Test Light
SGT27000 or equivalent 250-300 mA
incandescent bulb test lamp
The Refrigerant Cycle
During stabilized conditions (A/C system shutdown), the refrigerant pressures are equal throughout the
system. When the electric A/C compressor is in operation, it increases pressure on the refrigerant vapor,
raising its temperature. The high-pressure and high-temperature vapor is then released into the top of the A/C
condenser core.
The A/C condenser, being close to ambient temperature, causes the refrigerant vapor to condense into a liquid
when heat is removed from the refrigerant by ambient air passing over the fins and tubing. The now liquid
refrigerant, still at high pressure, exits from the bottom of the A/C condenser and enters the inlet side of the
A/C receiver/drier. The receiver/drier is designed to remove moisture from the refrigerant.
The outlet of the receiver/drier is connected to the Thermostatic Expansion Valve (TXV). The TXV provides
the orifice which is the restriction in the refrigerant system and separates the high and low pressure sides of
the A/C system. As the liquid refrigerant passes across this restriction, its pressure and boiling point are
reduced.
The liquid refrigerant is now at its lowest pressure and temperature. As it passes through the A/C evaporator,
it absorbs heat from the airflow passing over the plate/fin sections of the A/C evaporator. This addition of heat
causes the refrigerant to boil (convert to gas). The now cooler air can no longer support the same humidity
level of the warmer air and this excess moisture condenses on the exterior of the evaporator coils and fins and
drains outside the vehicle.
The refrigerant cycle is now repeated with the electric A/C compressor again increasing the pressure and
temperature of the refrigerant.
A thermistor which monitors the temperature of the air that has passed through the evaporator core controls
electric A/C compressor speed. If the temperature of the evaporator core discharge air is low enough to cause
the condensed water vapor to freeze, the electric A/C compressor reduces it speed.

The high-side line pressure is also monitored so that electric A/C compressor operation will be interrupted if
the system pressure becomes too high or is determined to be too low (low charge condition).
The electric A/C compressor thermal protection switch will interrupt compressor operation if the compressor
housing exceeds temperature limits.
The electric A/C compressor relief valve will open and vent refrigerant to relieve unusually high system
pressure.
NOTE: Verify the service disconnect plug is correctly inserted and locked into the LOCK position.
• A/C • Battery Junction Box
compressor (BJB) fuse:
♦ 13 (15A)
♦ 35 (40A)
♦ 47 (10A)
• Smart Junction Box (SJB)
fuse:
♦ 15 (10A)
♦ 37 (10A)
♦ 45 (5A)
• Circuitry
If the scan tool does not communication with the VCM :

• refer to Section 418-00 , No Power To The Scan Tool, to diagnose no power to the VCM .


• refer to Section 418-00 to diagnose no response from the HVAC module, Air Conditioning
Compressor Module (ACCM), Instrument Panel Cluster (IPC) or PCM.

418-00 .
• If the network test passes, retrieve and record the Continuous Memory Diagnostic Trouble
Codes (CMDTCs).
8. Clear the CMDTCs and carry out the self-test diagnostics for the HVAC, ACCM , IPC or PCM.
9. If the HVAC DTCs retrieved are related to the concern, go to the HVAC Module DTC Chart. If the
ACCM DTCs retrieved are related to the concern, go to the Air Conditioning Compressor Module
(ACCM) DTC Chart. If the PCM DTCs retrieved are related to the concern, go to the PCM DTC
Chart. For all other DTCs, refer to Section 419-10 .
NOTE: If no DTCs are present, GO to Symptom Chart - Climate Control Systems for the appropriate
diagnostic action.
HVAC Module and A/C Compressor Self-Test
During the self-test, the HVAC module will do the following:
• command airflow to PANEL vents

• command temperature blend door actuator to full cold
• set blower speed to level 4 and the 4th level will be displayed on the display
• illuminate the POWER, A/C and RECIRC button indicators
• flash the DEFROST, AUTO and rear window defrost button indicators
• command the A/C compressor to between 1,900 and 2,000 rpm
2. Observe the Electric A/C Compressor Speed (ACCM_ECS) Air Conditioning Compressor Module
(ACCM) PID.
3. At the same time, press and release the POWER and DEFROST buttons then, within 2 seconds, press
the RECIRC button.
4. Observe the HVAC module actions and A/C compressor speed.
5. To exit the self-test, press any climate control button or turn the ignition OFF.
• If the airflow is incorrect, refer to Section 412-00A .
• If the panel outlet temperature is incorrect, refer to Section 412-00A .
• If the blower is inoperative, GO to Pinpoint Test K .
• If the blower speed is incorrect, GO to Pinpoint Test L .
• If one or more indicators do not illuminate but the HVAC and A/C compressor operate
correctly, INSTALL a new Front Controls Interface Module (FCIM). Refer to Section 415-00
.
• If the ACCM_ECS PID reads 0 RPM, GO to Pinpoint Test I .
• If the ACCM_ECS PID reads between 1 and 1,899 rpm or greater than 2,000 rpm, INSTALL
a new electric A/C compressor. REFER to Section 412-01 . TEST the system for normal
operation.
• If all modes in the self-test are achieved, GO to Pinpoint Test E .

DTC Charts
PCM DTC Chart

P0532 A/C Pressure Refrigerant Sensor A REFER to Section 412-00A .
Circuit Low
P0533 A/C Refrigerant Pressure Sensor A REFER to Section 412-00A .
Circuit High
P2600 Coolant Pump A Control Circuit / GO to Pinpoint Test A .
Open
All Other - REFER to Powertrain Control/Emissions Diagnosis
DTCs (PC/ED) manual.
Air Conditioning Compressor Module (ACCM) DTC Chart

P0AFA:16 Hybrid Battery System GO to Pinpoint Test D .
Voltage Low: Circuit
P0AFB:17 Hybridattery System GO to Pinpoint Test D .
Voltage High: Circuit
B11EE:19 A/C Compressor: Current INSTALL a new electric A/C compressor. REFER to Section 412-01
Above Threshold . TEST the system for normal operation.
B11EE:49 A/C Compressor: InternalINSTALL a new electric A/C compressor. REFER to Section 412-01
Electronic Failure . TEST the system for normal operation.
B11EE:4B A/C Compressor: Over VERIFY the refrigerant charge level. REFER to Specifications in this
Temperature section. If the charge level is low, RECHARGE the system, CLEAR
the DTCs and REPEAT the self-test. TEST the system for normal
operation. If the DTC returns, INSTALL a new electric A/C
compressor. REFER to Section 412-01 . TEST the system for normal
operation.
U0100:00 Lost Communication With REFER to Section 418-00 to diagnose lost communication with the
ECM/PCM "A": No Sub ECM/PCM "A".
Type Information
U0155:00

Lost Communication With REFER to Section 418-00 to diagnose lost communication with the
Instrument Panel Cluster IPC module.
(IPC) Module: No Sub
Type Information
U0401:68 Invalid Data Received This DTC can set due to a fault in the PCM or because the PCM is
From ECM/PCM "A": unable to communicate over the Controller Area Network (CAN) bus.
Event Information CARRY OUT a self-test of the PCM. If the scan tool indicates that
the PCM is not responding, REFER to Section 418-00 to diagnose the
network communication concern. If PCM DTCs are present, REFER
to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
U0423:68 Invalid Data Received This DTC can set due to a fault in the Instrument Panel Cluster (IPC)
From Instrument Panel or because the IPC is unable to communicate over the CAN bus.
Cluster Control Module: CARRY OUT a self-test of the IPC . If the scan tool indicates that the
Event Information IPC is not responding, REFER to Section 418-00 to diagnose the
network communication concern. If IPC DTCs are present, REFER to
Section 413-01 to diagnose the IPC system fault.
U3000:49 Control Module: Internal INSTALL a new electric A/C compressor. REFER to Section 412-01
Electronic Failure . TEST the system for normal operation.
HVAC Module DTC Chart

B1081:07 Left Temperature Damper REFER to Section 412-00A .
Ground
Battery
Motor: Circuit Open
B1082:07 Right Temperature Damper REFER to Section 412-00A .
Ground
Battery


Motor: Circuit Open
B1083:07 Recirculation Damper GO to Pinpoint Test G .
Ground
Battery
Motor: Circuit Open
B1086:07 Air Distribution Damper REFER to Section 412-00A .
Motor: Mechanical Failures
Ground
Battery
Motor: Circuit Open
B10AF:12 Blower Fan Relay: Circuit GO to Pinpoint Test K .
Short to Battery
B10AF:14 Blower Fan Relay: Circuit If the blower motor is inoperative, GO to Pinpoint Test K .
If the blower motor relay is always on, GO to Pinpoint Test L .
B10B8:00 Push Buttons: No Sub Type Button held too long may set DTC. ATTEMPT to clean buttons.
Information CLEAR the DTCs. REPEAT the self-test. If code returns,
INSTALL a new Front Controls Interface Module (FCIM).
B10B9:12 Blower Control: Circuit GO to Pinpoint Test K .
Short to Battery
B10B9:14 Blower Control: Circuit If the blower motor is inoperative, GO to Pinpoint Test K .
If the blower motor is always on or operates incorrectly, GO to
Pinpoint Test L .
B11E5:11 Left HVAC Damper REFER to Section 412-00A .
Short to Ground
B11E5:15 Left HVAC Damper REFER to Section 412-00A .
B11E6:11 Right HVAC Damper REFER to Section 412-00A .
Short to Ground
B11E6:15 Right HVAC Damper REFER to Section 412-00A .
B11E7:11 Air Distribution Damper REFER to Section 412-00A .

Short to Ground
B11E7:15 Air Distribution Damper REFER to Section 412-00A .
B11F0:11 Air Intake Damper Position GO to Pinpoint Test G .
Ground
B11F0:15 Air Intake Damper Position GO to Pinpoint Test G .
Battery or Open
B1A61:11 Cabin Temperature Sensor: GO to Pinpoint Test B .
B1A61:15 Cabin Temperature Sensor: GO to Pinpoint Test B .
Circuit Short to Battery or
Open
B1A63:11 Right Solar Sensor: Circuit REFER to Section 412-00A .
Short to Ground
B1A63:15 Right Solar Sensor: Circuit REFER to Section 412-00A .
B1A64:11 Left Solar Sensor: Circuit REFER to Section 412-00A .
Short to Ground
B1A64:15 Left Solar Sensor: Circuit REFER to Section 412-00A .
B1A68:11 Ambient Temperature REFER to Section 412-00A .
Ground
B1A68:15 Ambient Temperature REFER to Section 412-00A .
Battery or Open
B1A69:11 Humidity Sensor: Circuit GO to Pinpoint Test C .
Short to Ground
B1A69:15 Humidity Sensor: Circuit GO to Pinpoint Test C .
B1B71:11 Evaporator Temperature REFER to Section 412-00A .
Ground
B1B71:15 Evaporator Temperature REFER to Section 412-00A .
Battery or Open
C1B14:11 Sensor Supply Voltage A: REFER to Section 412-00A .
C1B14:12 Sensor Supply Voltage A: REFER to Section 412-00A .
Body Control Module: No Smart Junction Box (SJB).
Instrument Panel Cluster IPC module.
(IPC) Module: No Sub Type
Information

navigation Control Module: Audio Control Module (ACM).
Front Controls Interface FCIM .
Module (FCIM) "A": No
U0422:68 Invalid Data Received From This DTC can set due to a fault in the SJB or because the SJB is
Body Control Module: unable to communicate over the Controller Area Network (CAN)
Event Information bus. CARRY OUT a self-test of the SJB . If the scan tool indicates
that the SJB is not responding, REFER to Section 418-00 to
diagnose the network communication concern. If SJB DTCs are
present, REFER to Section 419-10 .
U0423:68 Invalid Data Received From This DTC can set due to a fault in the IPC or because the IPC is
Instrument Panel Cluster unable to communicate over the CAN bus. CARRY OUT a
Control Module: Event self-test of the IPC . If the scan tool indicates that the IPC is not
Information responding, REFER to Section 418-00 to diagnose the network
communication concern. If IPC DTCs are present, REFER to
Section 413-01 to diagnose the IPC system fault.
U0464:68 Invalid Data Received From This DTC can set due to a fault in the Audio Control Module
Navigation Control Module: (ACM) or because the ACM is unable to communicate over the
Event Information CAN bus. CARRY OUT a self-test of the ACM . If the scan tool
indicates that the ACM is not responding, REFER to Section
418-00 to diagnose the network communication concern. If ACM
DTCs are present, REFER to Section 415-00 to diagnose the ACM
system fault
U0557:68 Invalid Data Received From This DTC can set due to a fault in the FCIM or because the FCIM
Front Controls Interface is unable to communicate over the CAN bus. CARRY OUT a
Module (FCIM) "A": Event self-test of the FCIM . If the scan tool indicates that the FCIM is
Information not responding, REFER to Section 418-00 to diagnose the network
communication concern. If FCIM DTCs are present, REFER to
Section 415-00 to diagnose the FCIM fault.
U1000:00 Solid State Driver INSTALL a new HVAC module. REFER to Section 412-01 .
Protection Activated-Driver
Disabled: No Sub Type
Information
U2100:00 Initial Configuration Not INSTALL a new HVAC module. REFER to Section 412-01 .
Information
U3000:41 Control Module: General INSTALL a new HVAC module. REFER to Section 412-01 .
Checksum Failure
U3000:49 Control Module: Internal INSTALL a new HVAC module. REFER to Section 412-01 .
Electronic Failure
U3002:62 Vehicle Identification INSTALL a new HVAC module. REFER to Section 412-01 .
Number: Signal Compare
Failure
U3003:16 Battery Voltage: Circuit REFER to Section 412-00A .
U3003:17 Battery Voltage: Circuit REFER to Section 412-00A .
- REFER to the Master DTC Chart in Section 419-10 .

All Other
DTCs
Symptom Chart - Climate Control Systems
Symptom Chart - Climate Control Systems

• No communication with the HVAC module
• Fuse(s)
• Circuitry open
• HVAC module communication network
• REFER to Section 418-00 .
• Unable to duplicate the customer concern and no DTCs present
• HVAC system and/or related components
• GO to Pinpoint Test E .
• Incorrect/erratic function in AUTO mode
• HVAC module
• GO to Pinpoint Test F .
• Reduced outlet airflow
• Cabin air filter

• Evaporator discharge air temperature sensor
• Blower motor
• Blower motor control
• PCM
• If the airflow is reduced only when in AUTO, A/C, MAX A/C, defrost or defrost/floor modes, GO to
Pinpoint Test J .
• If the airflow is reduced in all modes, INSPECT the cabin air filter. If the cabin air filter is clean and
free of damage and debris, GO to Pinpoint Test L .
• The air inlet door is inoperative
• Door actuator

• Air inlet door binding or stuck

• HVAC module
• GO to Pinpoint Test G .
• Incorrect/erratic direction of airflow from outlets
• Door actuator
• Mode door binding or stuck
• HVAC module
• Insufficient, erratic or no heat
• Low engine coolant level

• Engine overheating
• Plugged or partially plugged heater core
• Heater hose is kinked or binding
• GO to Pinpoint Test H .
• The air conditioning (A/C) is inoperative

• HVAC module
• PCM
• FCIM
• ACM
• ACCM
• GO to Pinpoint Test I .
• The air conditioning (A/C) is always on

• HVAC module
• PCM
• FCIM
• ACM
• ACCM
• GO to Pinpoint Test J .
• Temperature control is inoperative/does not operate correctly
• HVAC module

• The blower motor is inoperative
• Fuse(s)
• HVAC module
• GO to Pinpoint Test K .
• The blower motor does not operate correctly
• HVAC module
• GO to Pinpoint Test L .
• The dual temperature control is inoperative/does not operate correctly
• Temperature blend door/actuator broken/binding

• HVAC module - Electronic Automatic Temperature Control (EATC)
• Low A/C refrigerant charge
• NOTE: For the passenger side temperature setting on hybrid vehicles equipped with dual-zone
Electronic Automatic Temperature Control (EATC) and a Front Controls Interface Module (FCIM)
built on or after 4/08/2009 to be functional, a passenger must be seated in the front passenger seat. If
the front passenger seat is not occupied, the HVAC module will control the system based only on the
driver side temperature setting. The HVAC module receives a Medium Speed Controller Area
Network (MS-CAN) signal from the FCIM to indicate if the front passenger seat is occupied.
CHECK that the A/C system pressure is above 290 kPa (42 psi). If the pressure is below 290 kPa (42
psi), REFER to Section 412-00A . CHECK the temperature blend doors/actuators for a binding or
broken condition. If no condition is found, INSTALL a new HVAC dule.
• The temperature display will not switch between Celsius and Fahrenheit
• HVAC module
• INSTALL a new HVAC module. REFER to Section 412-01 .
• Inaccurate external temperature display
• HVAC module
• Ambient temperature sensor
Pinpoint Tests

Pinpoint Test A: DTC P2600
Normal Operation
Under normal operation, voltage is provided to the auxiliary coolant flow pump relay coil through circuit
CBK03 (GY). When the HVAC module is ON, a message is sent over the Controller Area Network (CAN) to
the PCM. When the PCM receives the message, a ground is provided to the auxiliary coolant flow pump relay
coil from the PCM through circuit CH307 (GY/BU), energizing the auxiliary coolant flow pump relay.
An auxiliary coolant flow pump is used only on hybrid vehicles to improve engine coolant circulation at low
engine speeds or when the engine is OFF.
The auxiliary coolant flow pump will be disabled when any of the following conditions are present:
• The climate control module is set to the OFF position.

• The ambient temperature is above 32°C (90°F).
• The coolant temperature is less than -10°C (14°F).
• The engine speed is above 4,000 rpm.
For a complete explanation of the auxiliary coolant flow pump refer to heating and ventilation in the
• DTC P2600 (Coolant Pump A Control Circuit / Open) - The DTC sets when the PCM grounds the
relay circd excessive current draw is detected on the relay circuit. The DTC also sets when the relay
circuit is OFF and no voltage is detected on the relay control circuit. The PCM expects to detect
voltage coming through the relay coil to the relay circuit when it is not grounding it.

• Heater pump relay
• PCM
PINPOINT TEST A: DTC P2600

A1 CHECK THE VOLTAGE TO THE RELAY
Yes
• Ignition OFF. CARRY OUT the auxiliary coolant flow
• Disconnect: Auxiliary Coolant Flow Pump Relay. pump relay component test.
• Ignition ON.
• Measure the voltage between ground and the Refer to Wiring Diagrams Cell 149 (
auxiliary coolant flow pump relay socket, circuit Fusion/MKZ , Fusion Hybrid/MKZ Hybrid
CBK03 (GY). ) for component testing.
If the relay tests OK, GO to A2 .
No

REPAIR circuit CBK03 (GY) for an open.


A2 CHECK CIRCUIT CH307 (GY/BU) FOR A
SHORT TO VOLTAGE
Yes
• Ignition OFF. REPAIR circuit CH307 (GY/BU) for a
• Disconnect: PCM C175t. short to voltage. CLEAR the DTCs.
• Ignition ON. REPEAT the self-test. TEST the system for
• Measure the voltage between ground and PCM normal operation.
C175t-42, circuit CH307 (GY/BU), harness side.
No
GO to A3 .

A3 CHECK CIRCUIT CH307 (GY/BU) FOR A
SHORT TO GROUND
Yes
• Measure the resistance between ground and PCM
C175t-42, circuit CH307 (GY/BU), harness side. No
REPAIR circuit CH307 (GY/BU) for a
REPEAT the self-test. TEST the system for
normal operation.

A4 CHECK CIRCUIT CH307 (GY/BU) FOR AN
OPEN
Yes
• Measure the resistance between auxiliary coolant GO to A5 .
flow pump relay socket, circuit CH307 (GY/BU)
and PCM C175t-42, circuit CH307 (GY/BU), No
harness side. REPAIR circuit CH307 (GY/BU) for an
operation.
PINPOINT TEST A: DTC P2600 4970


A5 CHECK THE PCM CONNECTION
Yes
• Clear the DTCs. INSTALL a new PCM. TEST the system
• Disconnect all the PCM connectors. for normal operation.
• Inspect the module connectors for:
♦ corrosion. No
♦ pushed-out pins. The system is operating correctly at this
♦ incorrectly seated connector. time. The concern may have been caused
• Connect and correctly seat all the PCM connectors. by a loose or corroded connector.
• Operate the system.
• Does the concern return?
Pinpoint Test B: DTC B1A61:11 and 15
Normal Operation
sensor from the HVAC module through circuit VH414 (GN/BU).
• DTC B1A61:11 (Cabin Temperature Sensor: Circuit Short to Ground) - The module senses excessive
voltage drop on the sensor reference voltage circuit, indicating a short directly to ground.
• DTC B1A61:15 (Cabin Temperature Sensor: Circuit Short to Battery or Open) - The module senses
no voltage drop on the sensor reference voltage circuit, indicating a short directly to voltage or an
open circuit.

• In-vehicle air temperature sensor
• HVAC module
PINPOINT TEST B: DTC B1A61:11 AND 15

B1 CHECK THE SENSOR RESISTANCE


• Disconnect: In-Vehicle Temperature/Humidity GO to B2 .
Sensor C2247.
• Measure the resistance ben the in-vehicle No
temperature/humidity sensor C2247-2, INSTALL a new in-vehicle
component side and C2247-5, component side temperature/humidity sensor. CLEAR the DTCs.
and compare to the table below. REPEAT the self-test. TEST the system for
normal operation.
Ambient
Temperature Resistance
-40°C (-40°F) 862,600-942,000
ohms
-15°C (5°F) 202,400-214,700
ohms
0°C (32°F) 93,510-97,640 ohms
15°C (59°F) 46,060-47,430 ohms
25°C (77°F) 29,700-30,300 ohms
35°C (95°F) 19,400-20,000 ohms
60°C (140°F) 7,414-7,774 ohms
85°C (185°F) 3,182-3,393 ohms
• Is the resistance within the specified values

for the temperatures?
B2 CHECK THE SENSOR OUTPUT VOLTAGE
Yes
• Ignition ON. INSTALL a new in-vehicle
• Measure the voltage between in-vehicle temperature/humidity sensor. CLEAR the DTCs.
temperature/humidity sensor C2247-2, circuit REPEAT the self-test. If code returns, GO to B8
VH414 (GN/BU), harness side and C2247-5, .
circuit RH111 (GY/BU), harness side.
No
For DTC B1A68:15 , GO to B3 .
For DTC B1A68:11 , GO to B6 .
PINPOINT TEST B: DTC B1A61:11 AND 15 4972

B3 CHECK CIRCUIT VH414 (GN/BU) FOR A

SHORT TO VOLTAGE
Yes
• Ignition OFF. REPAIR circuit VH414 (GN/BU) for a short to
• Disconnect: HVAC Module - Dual Automatic voltage. CLEAR the DTCs. REPEAT the
Temperature Control (DATC) C2356a. self-test. TEST the system for normal operation.
• Disconnect: HVAC Module - DATC C2356b.
• Ignition ON. No
• Measure the voltage between ground and GO to B4 .
HVAC module - DATC C2356b-21, circuit
VH414 (GN/BU), harness side.

B4 CHECK CIRCUIT VH414 (GN/BU) FOR AN
OPEN
Yes
• Measure the resi between HVAC module -
DATC C2356b-21, circuit VH414 (GN/BU), No
harness side and in-vehicle REPAIR circuit VH414 (GN/BU) for an open.
temperature/humidity sensor C2247-2, circuit CLEAR the DTCs. REPEAT the self-test. TEST
VH414 (GN/BU), harness side. the system for normal operation.

B5 CHECK CIRCUIT RH111 (GY/BU) FOR AN
OPEN
s
• Measure the resistance between HVAC GO to B8 .
module C2356a-10, circuit RH111 (GY/BU),
harness side and in-vehicle No
temperature/humidity sensor C2247-5, circuit REPAIR circuit RH111 (GY/BU) for an open.
RH111 (GY/BU), harness side. CLEAR the DTCs. REPEAT the self-test. TEST


B6 CHECK CIRCUIT VH414 (GN/BU) FOR A
SHORT TO CIRCUIT RH111 (GY/BU)
Yes
temperature/humidity sensor C2247-2, circuit REPAIR circuit VH414 (GN/BU) for a short to
VH414 (GN/BU), harness side and C2247-5, circuit RH111 (GY/BU). CLEAR the DTCs.
circuit RH111 (GY/BU), harness side. REPEAT the self-test. TEST the system for
normal operation.
Yes
• Measure the resistance between HVAC GO to B8 .
module - DATC C2356b-21, circuit VH414
(GN/BU), harness side and ground. No
REPAIR circuit VH414 (GN/BU) for a short to
ground. CLEAR the DTCs. REPEAT the
self-test. TEST the system for normal operation.

B8 CHECK THE MODULE CONNECTION
Yes
• Clear the DTCs. The concern may have been caused by a loose or
corroded connector. CLEAR the DTCs.

• Operate the system and verify the concern is REPEAT the self-test. TEST the system for
still present. normal operation.
Pinpoint Test C: DTC B1A69:11 or 15
Normal Operation
Under normal operation, the in-vehicle temperature/humidity sensor is grounded through circuit RH111
(GY/BU). A 5-volt reference voltage is supplied to the in-vehicle temperature/humidity sensor from the
HVAC module through circuit LH111 (BN/WH). The HVAC module receives the humidity value through
circuit VH413 (WH/BU).
• DTC B1A61:11 (Humidity Sensor: Circuit Short to Ground) - The module senses excessive voltage
drop on the sensor reference voltage circuit, indicating a short directly to ground.
• DTC B1A61:15 (Humidity Sensor: Circuit Short to Battery or Open) - The module senses no voltage
drop on the sensor reference voltage circuit, indicating a short directly to voltage or an open circuit.

• HVAC module
PINPOINT TEST C: DTC B1A69:11 OR 15

C1 CHECK THE SENSOR OUTPUT VOLTAGE
Yes
• Ignition OFF. INSTALL a new in-vehicle
• Disconnect: In-Vehicle Temperature/Humidity Sensor temperature/humidity sensor.
C2247. CLEAR the DTCs. REPEAT the
• Ignition ON. self-test. If code returns, GO to C7 .
• Measure the voltage between in-vehicle
temperature/humidity sensor C2247-4, circuit VH413 No
(WH/BU), harness side and C2247-5, circuit RH111 For DTC B1A69:15 , GO to C2 .
(GY/BU), harness side.
For DTC B1A69:11 , GO to C5 .

C2 CHECK CIRCUIT VH413 (WH/BU) FOR A SHORT TO

VOLTAGE
• Ignition OFF.
• Disconnect: HVAC Module - Dual Automatic Temperature
Control (DATC) C2356a.
• Ignition ON.
• Measure the voltage between ground and HVAC module -
DATC C2356b-20, circuit VH413 (WH/BU), harness side.
Yes
REPAIR circuit VH413 (WH/BU) for a short to voltage. CLEAR
the DTCs. REPEAT the self-test. TEST the system for normal
operation.
No
GO to C3 .
C3 CHECK CIRCUIT VH413 (WH/BU) FOR AN OPEN
Yes
• Measure the resistance between HVAC module - DATC
C2356b-20, circuit VH413 (WH/BU), harness side and No
in-vehicle temperature/humidity sensor C2247-4, circuit REPAIR circuit VH413 (WH/BU)
VH413 (WH/BU), harness side. for an open. CLEAR the DTCs.

C4 CHECK CIRCUIT RH111 (GY/BU) FOR AN OPEN
Yes
• Measure the resistance between HVAC module C2356a-10, GO to C7 .
circuit RH111 (GY/BU), harness side and in-vehicle
temperature/humidity sensor C2247-5, circuit RH111 No
(GY/BU), harness side. REPAIR circuit RH111 (GY/BU)
PINPOINT TEST C: DTC B1A69:11 OR 15 4976


Yes
temperature/humidity sensor C2247-4, circuit VH413 REPAIR circuit VH413 (WH/BU)
(WH/BU), harness side and C2247-5, circuit RH111 for a short to circuit RH111
(GY/BU), harness side. (GY/BU). CLEAR the DTCs.

GROUND
Yes
• Measure the resistance between HVAC module - DATC GO to C7 .
C2356b-20, circuit VH413 (WH/BU), harness side and
ground. No
RAIR circuit VH413 (WH/BU) for
a short to ground. CLEAR the
DTCs. REPEAT the self-test.
operation.

C7 CHECK THE MODULE CONNECTION
Yes
♦ corrosion. REFER to Section 412-01 . TEST
♦ pushed-out terminals. the system for normal operation.
• Clear the DTCs. this time. The concern may have
PINPOINT TEST C: DTC B1A69:11 OR 15 4977

• Operate the system and verify the concern is still present. been caused by a loose or corroded
Pinpoint Test D: DTC P0AFA:16 or P0AFB:17
Normal Operation
The Air Conditioning Compressor Module (ACCM) receives hybrid battery system voltage through circuit
HYT03 (OG/WH). The ACCM is grounded through circuit HYT04 (OG/BK).
• DTC P0AFA:16 (Hybrid Battery System Voltage Low: Circuit Voltage Below Threshold) - The
module senses when hybrid battery system voltage is less than 165 volts.
• DTC P0AFB:17 (Hybrid Battery System Voltage High: Circuit Voltage Above Threshold) - The
module senses when hybrid battery system voltage is greater than 450 volts.

• ACCM
PINPOINT TEST D: DTC P0AFA:16 OR P0AFB:17
WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and
service ructions, including instructions to depower the system. The high-voltage hybrid system utilizes
approximately 300 volts DC, provided through high-voltage cables to its components and modules. The
high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All
high-voltage components are marked with high-voltage warning labels with a high-voltage symbol.
Failure to follow these instructions may result in serious personal injury or death.
NOTE: Before carrying out the following test, diagnose any PCM or Battery Energy Control Module
(BECM) DTCs.

D1 CHECK THE DTCs FROM THE SELF-TEST
Yes
• Review the DTCs retrieved and recorded during DIAGNOSE all other BECM , PCM or TCM
Inspection and Verification. DTCs before diagnosing BECM DTCs
• Are there any other Battery Energy Control P0AFA:16 and P0AFB:17.
Module (BECM), PCM or Transmission
Control Module (TCM) DTCs present along For BECM DTCs, REFER to Section 414-03
with BECM DTCs P0AFA:16 and P0AFB:17? .
For PCM DTCs, REFER to the Powertrain

Control/Emissions Diagnosis (PC/ED)
manual.
For TCM DTCs, REFER to Section 307-01A

or Section 307-01B .
No
GO to D2 .
D2 CHECK THE HIGH-VOLTAGE BEC
HIGH-VOLTAGE LOW-CURRENT FUSE
Yes
WARNING: Never install the service GO to D3 .
disconnect plug with the high-voltage bussed
electrical center (BEC) cover removed. Always No
install the cover prior to connecting the service INSTALL a new high-voltage, low-current
disconnect plug. The high-voltage BEC cover fuse. INSPECT the high-voltage BEC for
prevents inadvertent contact with the high signs of an obvious short condition.
voltage which is present at several points INSTALL a new high-voltage BEC as
under the cover. Failure to follow these needed. If an obvious short condition is not
instructions may result in serious personal identified, CARRY OUT self-test of the
injury or death. Battery Energy Control Module (BECM).
REFER to Section 414-03 to diagnose BECM
• Ignition OFF. DTCs. CLEAR the DTCs from all modules.
• Depower the HVTB . Refer to Section 414-03 . REPEAT self-test.
• Remove the high-voltage Bussed Electrical
Center (BEC) cover. Refer to the High-Voltage
Low-Current Fuse procedure in Section 414-03 .
• Inspect and measure the resistance of the
high-voltage low-current fuse.
• Is the fuse undamaged and the resistance less

than 5 ohms?
D3 COMPARE THE ACCM HIGH VOLTAGE PID
WITH THE BECM HIGH VOLTAGE PID
Yes
• Ignition ON. CLEAR the DTCs from all modules.
• Enter the following diagnostic mode on the scan REPEAT the self-test. TEST the system for
tool: Hybrid Battery Pack Voltage normal operation. If the DTCs return ,
(BATPACKVOLT) Battery Energy Control INSTALL a new ACCM . REFER to Section
Module (BECM) PID. 412-01 . TEST the system for normal
• Enter the following diagnostic mode on the scan operation. If the DTCs do not return , the
tool: Electric A/C Compressor High Voltage system is operating correctly at this time. The
Supply (ACCM_CHVS) Air Conditioning concern may have been caused by a loose or
Compressor Module (ACCM) PID. corroded connector.
• Compare the BATPACKVOLT BECM PID
voltage with the ACCM_CHVS ACCM PID No
voltage. INSPECT the ACCM for loose or corroded
• Are both voltages approximately the same? connections. If OK, INSTALL a new ACCM
. REFER to Section 412-01 . TEST the
PINPOINT TEST D: DTC P0AFA:16 OR P0AFB:17 4979

Pinpoint Test E: Unable to Duplicate Customer Concern and No DTCs Present

• Incorrect functioning of the HVAC system
PINPOINT TEST E: UNABLE TO DUPLICATE CUSTOMER CONCERN AND NO DTCs PRESENT
NOTE: Diagnose any PCM, HVAC module or Air Conditioning Compressor Module (ACCM) DTCs before
carrying out the following pinpoint test.

E1 HVAC MODULE AND A/C
COMPRESSOR SELF-TEST
Yes
NOTE: If sent to this pinpoint test from GO to E2 .
the HVAC Module and A/C Compressor
Self-Test, GO to step E2 . No
Follow the actions within the HVAC Module and A/C
• Carry out the HVAC Module and A/C Compressor Self-Test.
Compressor Self-Test in this section.
• Were all modes in the self-test
achieved?
E2 CHECK THE BLOWER MOTOR
OPERATION
Yes
• Ignition ON. GO to E3 .
• Observe blower motor operation and No
select each blower motor speed. If the blower motor does not operate in any setting,
• Does the blower motor operate in all GO to Pinpoint Test K .
selections and change speed in each?
If the blower motor does not properly change speeds
or shut OFF, GO to Pinpoint Test L .
E3 CHECK AIRFLOW OPERATION
Yes
• Select the highest blower motor setting. GO to E4 .
• NOTE: Refer to Description and
Operation in this section for proper No
airflow descriptions. REFER to Section 412-00A and DIAGNOSE for
• While observing the airflow, select each incorrect/erratic direction of airflow from outlets.
of the airflow positions (PANEL,
PANEL/FLOOR, FLOOR,
FLOOR/DEFROST, DEFROST).
• Is the airflow directed to the proper
outlets?
E4 VERIFY TEMPERATURE CONTROL
OPERATION

4980
• Start the vehicle and allow it to reach Yes

normal operating temperature. GO to E5 .
• With the A/C OFF, select PANEL mode.
• Change the temperature setting from the No
coldest to the warmest and back to the If the temperature does not get very warm or heat is
coldest. erratic, GO to Pinpoint Test H .
• Does the temperature change between
very warm to cool? If the temperature does not change at all, REFER to
Section 412-00A and DIAGNOSE for temperature
control is inoperative/does not operate correctly.
E5 VERIFY NO A/C COMPRESSOR
OPERATION WITH A/C OFF
Yes
• With the A/C OFF, select PANEL mode. GO to E6 .
• Select the coldest temperature setting.
• Is the outlet temperature close to No
ambient temperature? If the temperature is warmer than ambient
temperature, REFER to Section 412-00A and
DIAGNOSE for temperature control is
inoperative/does not operate correctly.
If the outlet temperature is significantly colder than

ambient temperature, GO to Pinpoint Test J .
E6 VERIFY A/C OPERATION IN THE A/C
MODE
Yes
• Make sure the ambient air temperature is GO to E7 .
above 2°C (35°F).
• Press the A/C button (indicator ON). GO to Pinpoint Test I .
• Does the A/C operate when the PANEL
and A/C button (indicator ON) is
pressed?
E7 CHECK THE RECIRC OPERATION
Yes
• Press the RECIRC button (indicator GO to E8 .
OFF).
• Select the highest blower motor setting. GO to Pinpoint Test G .
• Observe airflow noise.
• Does the airflow noise increase when

the RECIRC mode is selected
(indicator ON)?
E8 CHECK IN-VEHICLE
TEMPERATURE/HUMIDITY SENSOR FAN
OPERATION

4981
• Make sure the ambient air temperature is Yes

above 2°C (35°F). GO to E9 .
• Press the A/C button (indicator ON). No
• Place a piece of tissue within 25 mm (1 GO to Pinpoint Test F .
in) of the in-vehicle temperature/humidity
sensor opening.
• Is the tissue drawn to the sensor

opening?
E9 CHECK AUXILIARY COOLANT
FLOW PUMP OPERATION
Yes
• Allow the vehicle to cool to ambient The system is operating normally.
temperature.
• Start the engine and let the engine idle If sent here for reduced airflow, CHECK the cabin air
until it shuts down automatically, filter. If the cabin air filter is dirty, INSTALL a new
• Select FLOOR mode. cabin air filter. TEST the system for normal
• Set the temperature to the warmest operation. If reduced airflow is still observed or the
setting. cabin air filter is clean, GO to Pinpoint Test L .
• Select the highest blower motor setting.
• Does the discharge air temperature No
closely maintain its warm temperature GO to Pinpoint Test H .
for an extended period of time?
Pinpoint Test F: Incorrect/Erratic Function in AUTO Mode
Normal Operation
sensor from the HVAC module through circuit VH414 (GN/BU). To accurately monitor the cabin air
temperature, the in-vehicle air temperature sensor uses an integral fan to draw cabin air to the sensor, inside
the instrument panel. The fan is supplied voltage through circuit CBP37 (WH) and ground from circuit
GD116 (BK/VT)

• HVAC module

PINPOINT TEST F: INCORRECT/ERRATIC FUNCTION IN AUTO MODE

F1 CHECK IN-VEHICLE
TEMPERATURE/HUMIDITY SENSOR FAN
OPERATION
Yes
• Make sure the ambient air temperature is above 2°C
(35°F). No
• Select PANEL mode. GO to F3 .
• Press the A/C button (indicator ON).
• Place a piece of tissue within 25 mm (1 in) of the
in-vehicle temperature/humidity sensor opening.
• Is the tissue drawn to the sensor opening?

F2 CHECK THE SENSOR RESISTANCE
Yes
• Disconnect: In-Vehicle Temperature/Humidity Sensor
C2247.
• Measure the resistance between the in-vehicle
temperature/humidity seor C2247-2, component side
and C2247-5, component side and compare to the
table below.

-40°C (-40°F) 862,600-942,000 ohms
-15°C (5°F) 202,400-214,700 ohms
0°C (32°F) 93,510-97,640 ohms
15°C (59°F) 46,060-47,430 ohms
25°C (77°F) 29,700-30,300 ohms
35°C (95°F) 19,400-20,000 ohms
60°C (140°F) 7,414-7,774 ohms
85°C (185°F) 3,182-3,393 ohms
PINPOINT TEST F: INCORRECT/ERRATIC FUNCTION IN AUTO MODE 4983


temperatures?
F3 CHECK CIRCUIT SBP37 (WH) FOR VOLTAGE
Yes
• Measure the voltage between in-vehicle
temperature/humidity sensor C2247-6, circuit SBP37 No
(WH), harness side and ground. VERIFY Smart Junction Box (SJB) fuse
37 (10A) is OK. If OK, REPAIR circuit
SBP37 (WH) for an open. TEST the
system for normal operation. If not OK,
REFER to the Wiring Diagrams manual
to identify the possible causes of the
circuit short.

F4 CHECK CIRCUIT GD116 (BK/VT) FOR GROUND
Yes
• Ignition OFF. INSTALL a new in-vehicle
• Measure the resistance between in-vehicle temperature/humidity sensor. TEST the
temperature/humidity sensor C2247-1, circuit GD116 system for normal operation.
(BK/VT), harness side and ground.
No
REPAIR circuit GD116 (BK/VT) for an
open. TEST the system for normal
operation.

F5 CHECK THE MODULE CONNECTION
Yes
• Inspect the module connectors for: INSTALL a new HVAC module. REFER
♦ corrosion. to Section 412-01 . TEST the system for
♦ pushed-out terminals. normal operation.
PINPOINT TEST F: INCORRECT/ERRATIC FUNCTION IN AUTO MODE 4984

• Is the concern still present? self-test. TEST the system for normal
operation.
Pinpoint Test G: The Air Inlet Door is Inoperative
Normal Operation
Under normal operation, to rotate the air inlet door actuator, the HVAC module - Dual Automatic
Temperature Control (DATC) supplies voltage to the air inlet door actuator motor through the circuit CH207
(BU/GY) or through circuit CH208 (GN/OG). To rotate the air inlet door actuator in the reverse direction, the
HVAC module - DATC reverses the voltage and ground circuits.
The air inlet door actuator feedback resistor is supplied a ground from the HVAC module - DATC through
circuit RH111 (GY/BU) and a 5-volt reference voltage on circuit LH111 (BN/WH). The HVAC module -
DATC reads the voltage on the air inlet door actuator feedback circuit VH438 (GN/VT) to determine the air
inlet door actuator position by the position of the actedback resistor wiper arm.

The module senses no changes in the feedback circuit when
• B1083:07 - Recirculation Damper motor movement is commanded and no motor DTCs are
Motor: Mechanical Failures present.
• B1083:11 - Recirculation Damper reference voltage circuit, indicating a short directly to ground.
Motor: Circuit Short to Ground
The module senses no voltage drop on the sensor reference
• B1083:12 - Recirculation Damper voltage circuit, indicating an open circuit.
Motor: Circuit Short to Battery
• B1083:13 - Recirculation Damper reference voltage circuit, indicating a short directly to ground.
Motor: Circuit Open
The module senses no voltage drop on the sensor reference
• B11F0:11 - Air Intake Damper voltage circuit, indicating an open circuit.
Position Sensor: Circuit Short to
Ground
• B11F0:15 - Air Intake Damper reference voltage circuit, indicating a short directly to ground.
Position Sensor: Circuit Short to
Battery or Open
This pinpoint test is intended to diagnose t:

• Air inlet door actuator motor
• HVAC module

PINPOINT TEST G: THE AIR INLET DOOR IS INOPERATIVE

G1 CHECK THE HVAC MODULE FOR
DTCs
Yes
• Ignition ON. For DTC B1083:07 , INSPECT for
• Check the HVAC module for DTCs. binding/damaged linkage or door. REPAIR as
• Are DTCs present? necessary. If no condition is found, INSTALL a new
door actuator. CLEAR the DTCs. REPEAT the
self-test. TEST the system for normal operation. For
DTC B1083:11 , GO to G2 .
For DTC B1083:12 , GO to G3 .
For DTC B1083:13 , GO to G4 .
For DTC B11F0:11 , GO to G6 .
For DTC B11F0:15 , GO to G8 .
No
INSPECT for broken/binding linkage or door.
REPAIR as necessary. If no condition is found, GO
to G13 .
G2 CHECK CIRCUITS CH207 (BU/GY) AND
CH208 (GN/OG) FOR A SHORT TO
GROUND
Yes
• Disconnect: HVAC Module - DATC
C2356a. No
• Measure the resistance between ground REPAIR circuit CH207 (BU/GY) or CH208
and: (GN/OG) for a short to ground. CLEAR the DTCs.
♦ HVAC module - DATC REPEAT the self-test. TEST the system for normal
C2356a-16, circuit CH208 operation.
♦ HVAC module - DATC
C2356a-1cuit CH207 (BU/GY),
harness side.

ohms?
PINPOINT TEST G: THE AIR INLET DOOR IS INOPERATIVE 4986

G3 CHECK CIRCUITS CH207 (BU/GY) AND

CH208 (GN/OG) FOR A SHORT TO
VOLTAGE
Yes
• Ignition OFF. REPAIR circuit CH207 (BU/GY) or CH208
• Disconnect: HVAC Module - DATC (GN/OG) for a short to power. CLEAR the DTCs.
C2356a. REPEAT the self-test. TEST the system for normal
♦ HVAC module - DATC No
C2356a-16, circuit CH208 GO to G5 .
♦ HVAC module - DATC
C2356a-15, circuit CH207

G4 CHECK THE ACTUATOR MOTOR
DRIVE CIRCUITS FOR AN OPEN
Yes
NOTE: Due to limited connector GO to G13 .
accessibility, before carrying out this test
step, visually inspect the wiring between No
the HVAC module and actuator for opens REPAIR the circuit(s) for an open. TEST the system
or shorts. If no damage is visually evident, for normal operation.
proceed with the test.
• Ignition OFF.
C2356a.
• Disconnect: Air Inlet Door Actuator C289.
module - DATC C2356a-15, circuit
CH207 (BU/GY), harness side and air inlet
mode door actuator C289-6, circuit CH207


CH208 (GN/OG), harness side and air
inlet mode door actuator C289-5, circuit
CH208 (GN/OG), harness side.

G5 CHECK CIRCUIT CH207 (BU/GY) FOR
A SHORT TO CIRCUIT CH208 (GN/OG)
Yes
• Measure the resistance between HVAC No
module - DATC C2356a-15, circuit REPAIR circuit CH208 (GN/OG) for a short to
CH207 (BU/GY), harness sidd HVAC circuit CH207 (BU/GY). CLEAR the DTCs.
module - DATC C2356a-16, circuit REPEAT the self-test. TEST the system for normal
CH208 (GN/OG), harness side. operation.

ohms?
G6 CHECK CIRCUIT VH438 (GN/VT) FOR
A SHORT TO GROUND
Yes
C2356a. No
• Measure the resistance between ground REPAIR circuit VH438 (GN/VT) for a short to
and HVAC module - DATC C2356a-3, ground. CLEAR the DTCs. REPEAT the self-test.
circuit VH438 (GN/VT), harness side. TEST the system for normal operation.


ohms?
G7 CHECK CIRCUITS RH111 (GY/BU) AND
VH438 (GN/VT) FOR A SHORT TOGETHER
Yes
the HVAC module and actuator for opens REPAIR circuits VH438 (GN/VT) and RH111
or shorts. If no damage is visually evident, (GY/BU) for a short together. CLEAR the DTCs.
proceed with the test. REPEAT the self-test. TEST the system for normal
operation.
RH111 (GY/BU), harness side and HVAC
module C2356a-3, circuit VH438
(GN/VT), harness side.

ohms?
A SHORT TO POWER
Yes
• Ignition OFF. REPAIR circuit VH438 (GN/VT) for a short to
• Disconnect: HVAC Module - DATC power. CLEAR the DTCs. REPEAT the self-test.
C2356a. TEST the system for normal operation.
• Ignition ON.
• Measure the voltage between ground and No
HVAC module - DATC C2356a-3, circuit GO to G9 .
VH438 (GN/VT), harness side.


G9 CHECK CIRCUITS LH111 (BN/WH)
AND VH438 (GN/VT) FOR A SHORT
TOGETHER
Yes
the HVAC module and actuator for opens REPAIR circuits VH438 (GN/VT) and LH111
or shorts. If no damage is visually evident, (BN/WH) for a short together. CLEAR the DTCs.
proceed with the test. REPEAT the self-test. TEST thetem for normal
operation.
LH111 (BN/WH), harness side and HVAC
module - DATC C2356a-3, circuit VH438

ohms?
AN OPEN
Yes
• Measure the resistance between HVAC GO to G11 .
module - DATC C2356a-3, circuit VH438
(GN/VT), harness side and air inlet door No
actuator C289-9, circuit VH438 (GN/VT), REPAIR circuit VH438 (GN/VT) for an open.
harness side. CLEAR the DTCs. REPEAT the self-test. TEST the


G11 CHECK CIRCUIT LH111 (BN/WH)
FOR AN OPEN
Yes
LH111 (BN/WH), harness side and air No
inlet door actuator C289-10, circuit LH111 REPAIR circuit LH111 (BN/WH) for an open.
(BN/WH), harness side. CLEAR the DTCs. REPEAT the self-test. TEST the

G12 CHECK THE ACTUATOR RETURN
CIRCUIT RH111 (GY/BU) FOR AN OPEN
Yes
RH111 (GY/BU), harness side and air inlet No
door actuator C289-8, circuit RH111 REPAIR circuit RH111 (GY/BU) for an open.
(GY/BU), harness side. CLEAR the DTCs. REPEAT the self-test. TEST the

G13 CHECK THE ACTUATOR
CONNECTION
Yes
• Inspect the connector for: CARRY OUT the Air Inlet Mode Door Actuator
♦ corrosion. component test in this section. If the actuator tests
♦ pushed-out terminals. OK, GO to G14 .
• Connect and correctly seat the actuator No
connector. The system is operating correctly at this time. The
• Clear the DTCs. concern may have been caused by a loose or
• Operate the system and verify the concern corroded connector. CLEAR the DTCs. TEST the
is still present. system for normal operation.
G14 MODULE ACTUATOR POSITION
CALIBRATION

NOTE: The purpose of the module Yes

actuator position calibration is to allow the INSTALL a new HVAC module. REFER to Section
HVAC module to reinitialize and calibrate 412-01 . TEST the system for normal operation.
the actuator stop points. To carry out the
calibration, follow the steps below. No
The system is now operating correctly at this time.
• Ignition OFF. The concern may have been caused by a foreign
• Inspect the module connectors for: object in the HVAC case or temporary binding that
♦ corrosion. restricted actuator door travel. CHECK any actuator
♦ pushed-out terminals. external linkage. If condition recurs, INSPECT
♦ damaged terminals. actuator linkage and door for binding and CHECK
• Connect and correctly seat all the HVAC HVAC case for foreign objects.
module connectors.
• Ignition ON.
• Clear the DTCs.
• Select any position except OFF
• NOTE: The HVAC module will now
initialize and calibrate the actuators.
Calibration of the actuators will take
approximately 30 seconds.
• Operate the system and verify the concern
is still present.
Pinpoint Test H: Insufficient, Erratic or No Heat
Normal Operation
Under normal operation, warm coolant flows from the engine through the auxiliary coolant flow pump to the
heater core and back to the engine. The auxiliary coolant flow pump relay (switch side) is supplied voltage
through circuit SBB13 (GY/RD). When the relay is energized by the PCM, the voltage is sent from the relay
to the auxiliary coolant flow pump through circuit CHC01 (BN/YE). The auxiliary coolant flow pump is
grounded through circuit GD112 (BK/YE). When the HVAC module is ON, a message is sent over the
Controller Area Network (CAN) to the PCM. When the PCM receives the message, the PCM energizes the
auxiliary coolant flow pump relay.
An auxiliary coolant flow pump is used only on hybrid vehicles to improve engine coolant circulation for
heater operation at low engine speeds or when the engine is OFF.

For a complete explanation of the auxiliary coolant flow pump, refer to heating and ventilation in the

• Plugged heater core
• Coolant level
• Temperature blend door
• Auxiliary coolant flow pump
• PCM
• HVAC module
PINPOINT TEST H: INSUFFICIENT, ERRATIC OR NO HEAT

H1 CHECK FOR CORRECT ENGINE
COOLANT LEVEL
Yes
• Check the engine coolant level when hot
and cold. No
• Is the engine coolant at the correct level GO to H2 .
(hot/cold) as indicated on the engine
coolant recovery reservoir?
H2 CHECK THE ENGINE COOLING
SYSTEM FOR LEAKS
Yes
• Pressure test the cooling system for leaks. REPAIR the engine coolant leak. TEST the system
Refer to Section 303-03A . for normal operation.
• Does the engine cooling system leak?
No
FILL and BLEED the cooling system. REFER to
Section 303-03A . After filling and bleeding the
cooling system, GO to H3 .
H3 CHECK FOR COOLANT FLOW TO THE
HEATER CORE
Yes
• Start the engine and let the engine idle until GO to H4 .
it shuts down automatically,
• Select FLOOR mode. No
• Set the temperature to the warmest setting. GO to H5 .
• Select the lowest blower motor setting.
• Using a suitable temperature measuring
device, check the heater core inlet hose to
see if it is hot.
• Is the heater core inlet hose hot?
PINPOINT TEST H: INSUFFICIENT, ERRATIC OR NO HEAT 4993

H4 CHECK FOR A PLUGGED OR

RESTRICTED HEATER CORE
Yes
• Using a suitable temperature measuring REFER to Section 412-00A and diagnose for
device, measure the heater core outlet hose temperature control is inoperative/does not operate
temperature. correctly.
No
INSTALL a new heater core. TEST the system
forormal operation.
• Is the heater core outlet hose temperature

similar to the inlet hose temperature
(within approximately 6-17°C [10-30°F])?
H5 CHECK FOR COOLANT FLOW TO THE
AUXILIARY COOLANT FLOW PUMP
Yes
• Using a suitable temperature measuring GO to H6 .
device, check the auxiliary coolant flow
pump inlet hose to see if it is hot. No
• Is the auxiliary coolant flow pump inlet REFER to Section 303-03B to check cooling
hose hot? system function.
H6 CHECK CIRCUIT CHC01 (BN/YE) FOR
VOLTAGE
Yes
• Disconnect: Auxiliary Coolant Flow Pump
C1450. No
• Ignition ON. CARRY OUT the auxiliary coolant flow pump
• Enter the following diagnostic mode on the relay component test.
scan tool: DataLogger - PCM.
• Toggle the Heater Pump Commanded Refer to Wiring Diagrams Cell 149 ( Fusion/MKZ ,
(HPUMP) output command ON. Fusion Hybrid/MKZ Hybrid ) for component
• Measure the voltage between auxiliary testing.
coolant flow pump C1450-2, circuit CHC01
(BN/YE), harness side and ground. If the relay tests OK, GO to H8 .

H7 CHECK CIRCUIT GD121 (BK/YE) FOR
GROUND
PINPOINT TEST H: INSUFFICIENT, ERRATIC OR NO HEAT 4994


• Measure the voltage between auxiliary INSTALL a new auxiliary coolant flow pump.
coolant flow pump C1450-1, circuit GD121 REFER to Section 412-01 . TEST the system for
(BK/YE), harness side and auxiliary coolant normal operation.
flow pump C1450-2, circuit CHC01
(BN/YE), harness side. No
REPAIR circuit GD121 (BK/YE) for an open.

H8 CHECK THE AUXILIARY COOLANT
FLOW PUMP RELAY VOLTAGE SUPPLY
Yes
• Ignition OFF. REPAIR circuit CHC01 (BN/YE) for an open.
• Disconnect: Auxiliary Coolant Flow Pump TEST the system for normal operation.
Relay.
• Ignition ON. No
• Measure the voltage between ground and VERIFY Battery Junction Box (BJB) fuse 13
auxiliary coolant flow pump relay socket, (15A) is OK. If OK, REPAIR circuit SBB13
circuit SBB13 (GY/RD). (GY/RD) for an open. TEST the system for normal
operation. If not OK, REFER to the Wiring
Diagrams manual to identify the possible causes of
the circuit short.
Pinpoint Test I: The Air Conditioning (A/C) is Inoperative
Normal Operation
Under normal operation, for vehicles equipped with navigation, when the A/C button is pressed, a message is
sent from the Front Controls Interface Module (FCIM) over the Medium Speed Controller Area Network
(MS-CAN) bus to the HVAC module. The HVAC module then sends an A/C request message over the
MS-CAN bus to the Instrument Cluster (IC), then from the IC through the High Speed Controller Area
Network (HS-CAN) bus to the PCM.
For vehicles equipped with navigation, when MAX A/C is selected on the touch screen, the Audio Control
Module (ACM) sends a message over the MS-CAN bus to the HVAC module that MAX A/C has been

selected.
For vehicles not equipped with navigation, when A/C is requested, a message is sent from the HVAC module
over the MS-CAN bus to the IC , then from the IC through the HS-CAN bus to the PCM.
are met:
transducer.
to raise or lower the electric A/C compressor speed as required.

• HVAC module
• PCM
• FCIM
• ACM
• Electric A/C compressor
PINPOINT TEST I: THE AIR CONDITIONING (A/C) IS INOPERATIVE
NOTE: Diagnose any PCM, HVAC module or ACCM DTCs before carrying out the following pinpoint test.
NOTE: Before carrying out the following test, check that the A/C system pressure is above 290 kPa (42 psi).
If the pressure is below 290 kPa (42 psi), refer to Section 412-00A in this section.

I1 CHECK THE A/C PRESSURE SENSOR (ACP_PRESS) PCM
PID
Yes
ACP_PRESS PCM PID. No
• With the manifold gauge set connected, compare the pressure INSTALL a new A/C pressure
readings of the manifold gauge set and the ACP_PRESS PID. transducer. TEST the system for
• Are the pressure values of the manifold gauge set and the normal operation.
ACP_PRESS PID similar?
I2 CHECK THE A/C EVAPORATOR TEMPERATURE
Yes
• Allow the vehicle exterior and interior to stabilize to an For vehicles not equipped with
PINPOINT TEST I: THE AIR CONDITIONING (A/C) IS INOPERATIVE 4996

ambient temperature. navigation, GO to I3 .

EVAP_TEMP HVAC PID. For vehicles equipped with
• Does the EVAP_TEMP HVAC PID read similar to the navigation, GO to I4 .
ambient temperature?
No
INSTALL a new A/C
temperature sensor. TEST the
I3 CHECK THE (A/C) SWITCH (CC_SW_AC) HVAC PID
WITH THE A/C ON
Yes
• Start the engine. GO to I5 .
CC_SW_AC HVAC PID. No
• Select PANEL and press the A/C button (indicator OFF). GO to I6 .
• Does the CC_SW_AC HVAC PID read Active?
I4 CHECK THE (A/C) SWITCH (CC_SW_AC) FCIM PID
WITH THE A/C ON
Yes
NOTE: Before carrying out this test step, be sure all other GO to I5 .
FCIM button functions are operational. If all other buttons
operate correctly, continue with this test step. If multiple No
buttons are inoperative and DTC U0256:00 is not present, INSTALL a new FCIM .
install a new FCIM . Test the system for normal operation. If REFER to Section 415-00 .
DTC U0256:00 is present, diagnose the DTC first. TEST the system for normal
operation.
CC_SW_AC FCIM PID.
• Select PANEL and press the A/C button (indicator on).
• Does the CC_SW_AC FCIM PID read Active?
I5 CHECK THE AIR CONDITIONING COMPRESSOR
ON
Yes
• Enter the following diagnostic mode on the scan tool: GO to I8 .
ACC_CMD PCM PID.
GO to I7 .
I6 CHECK THE MODULE CONNECTION
Yes
PINPOINT TEST I: THE AIR CONDITIONING (A/C) IS INOPERATIVE 4997

operation.
I7 CHECK THE PCM CONNECTION
Yes
• Clear the DTCs. INSTALL a new PCM. TEST
• Disconnect all of the PCM connectors. the system for normal
• Check for: operation.
♦ corrosion.
♦ damaged terminals. The system is operating
• Connect and correctly seat all of the PCM connectors. correctly at this time. The
• Operate the system. concern may have been caused
• Does the concern return? by a loose or corroded
connector.
I8 CHECK ACCM OPERATING CONDITIONS
Yes
• Make sure the following conditions are met: The system is operating
♦ The PCM does not detect excessively high or low correctly at this time. The
refrigerant pressure from the A/C pressure transducer. concern may have been caused
♦ The PCM does not detect excessively high engine by attempting to operate the
coolant temperature. A/C outside of operating
♦ The PCM does not detect an ambient air temperature conditions.
below -1°C (30°F).
♦ The PCM has not detected a Wide Open Throttle No
(WOT) condition. INSTALL a new electric A/C
♦ The HVAC module does not detect an evaporator compressor. REFER to Section
discharge air temperature below 2°C (36°F). 412-01 . TEST the system for
• Start the engine. normal operation.
• Select PANEL and press the A/C button (indicator on).
• Does the A/C operate?
Pinpoint Test J: The Air Conditioning (A/C) is Always On
Normal Operation
Under normal operation, for vehicles equipped with navigation, when the A/C button is pressed, a message is
sent from the Front Controls Interface Module (FCIM) over the Medium Speed Controller Area Network
(MS-CAN) bus to the HVAC module. The HVAC module then sends an A/C request message over the
MS-CAN bus to the Instrument Cluster (IC), then from the IC through the High Speed Controller Area
Network (HS-CAN) bus to the PCM.
For vehicles equipped with navigation, when MAX A/C is selected on the touch screen, the Audio Control
Module (ACM) sends a message over the MS-CAN bus to the HVAC module that MAX A/C has been
selected.
For vehicles not equipped with navigation, when A/C is requested, a message is sent from the HVAC module

over the MS-CAN bus to the IC , then from the IC through the HS-CAN bus to the PCM.
are met:
transducer.
to raise or lower the electric A/C compressor speed as required.

• HVAC module
• FCIM
• ACM
• Electric A/C compressor
PINPOINT TEST J: THE AIR CONDITIONING (A/C) IS ALWAYS ON
NOTE: Diagnose any PCM, HVAC module or ACCM DTCs before carrying out the following pinpoint test.

J1 CHECK THE A/C EVAPORATOR TEMPERATURE
Yes
• Allow the vehicle exterior and interior to stabilize to an ambient For vehicles not equipped
temperature. with navigation, GO to J2 .
• Ignition ON.
• Enter the following diagnostic mode on the scan tool: For vehicles equipped with
EVAP_TEMP HVAC PID. navigation, GO to J3 .
• Does the EVAP_TEMP HVAC PID read similar to the ambient
temperature? No
INSTALL a new A/C
temperature sensor. TEST
operation.
J2 CHECK THE (A/C) SWITCH (CC_SW_AC) HVAC PID WITH
THE A/C OFF
Yes
• Start the engine. GO to J4 .
• Enter the following diagnostic mode on the scan tool: CC_SW_AC
HVAC PID. No
• Select PANEL and make sure the A/C indicator is OFF. INSTALL a new HVAC
PINPOINT TEST J: THE AIR CONDITIONING (A/C) IS ALWAYS ON 4999

• Does the CC_SW_AC HVAC PID read Inactive? module. REFER to Section
412-01 . TEST the system
J3 CHECK THE (A/C) SWITCH (CC_SW_AC) FCIM PID WITH
THE A/C OFF
Yes
NOTE: Before carrying out this test step, be sure all other FCIM GO to J4 .
button functions are functioning correctly. If all other buttons
operate correctly, continue with this test step. If multiple buttons No
are incorrectly functioning and DTC U0256:00 is not present, INSTALL a new FCIM .
install a new FCIM . Test the system for normal operation. If DTC REFER to Section 415-00 .
U0256:00 is present, diagnose the DTC first. TEST the system for normal
operation.
• Enter the following diagnostic mode on the scan tool: CC_SW_AC
FCIM PID.
• Select PANEL and make sure the A/C indicator is OFF.
• Does the CC_SW_AC FCIM PID read Inactive?
J4 CHECK THE AIR CONDITIONING COMPRESSOR
OFF
Yes
• Enter the following diagnostic mode on the scan tool: ACC_CMD INSTALL a new electric
PCM PID. A/C compressor. REFER to
• Select PANEL and make sure the A/C indicator is OFF. Section 412-01 . TEST the
• Does the ACC_CMD PCM PID read OFF? system for normal
operation.
No
INSTALL a new PCM.
operation.
Pinpoint Test K: The Blower Motor is Inoperative
Normal Operation
to the relay switch contact through circuit SBB35 (BU/RD). When the relay coil is energized, voltage is
speed.


The module senses excessive voltage on the relay coil ground
• B10AF:12 - Blower Fan Relay: circuit, indicating a short directly to voltage.
The module senses no voltage on the relay coil ground circuit,
• B10AF:14 - Blower Fan Relay: indicating an open or a short directly to ground.
Circuit Short to Ground or
Open
The module senses excessive voltage on the blower motor control
• B10B9:12 - Blower Control: PWM circuit, indicating a short directly to voltage.
The module senses no voltage on the blower motor control PWM
• B10B9:14 - Blower Control: circuit, indicating an open or a short directly to ground.
Circuit Short to Ground or
Open

• Fuse(s)
• HVAC module - Dual Automatic Temperature Control (DATC)
• Blower motor
PINPOINT TEST K: THE BLOWER MOTOR IS INOPERATIVE

K1 CHECK THE HVAC MODULE FOR
DTCs
Yes
• Check the HVAC module for DTCs. (VT/GN) for a short to voltage. CLEAR the DTCs.
• Are any DTCs present? REPEAT the self-test. TEST the system for normal
operation.
For DTC B10AF:14 , CARRY OUT the Blower

Motor Relay component test.
Refer to Wiring Diagrams Cell 149 ( Fusion/MKZ ,

Fusion Hybrid/MKZ Hybrid ) for component testing.
If the relay tests OK, GO to K2 .
For DTC B10B9:14 , GO to K4 .
For DTC B10B9:12, REPAIR circuit VH101

(VT/WH) for a short to voltage. CLEAR the DTCs.
REPEAT the self-test. TEST the system for normal
operation.
PINPOINT TEST K: THE BLOWER MOTOR IS INOPERATIVE 5001

No
GO to K6 .
K2 CHECK THE RELAY COIL SUPPLY
VOLTAGE
Yes
• Disconnect: Blower Motor Relay.
• Ignition ON. No
• Measure the voltage between blower VERIFY Smart Junction Box (SJB) fuse 45 (5A) is
motor relay socket pin 1, circuit CBP45 OK. If OK, REPAIR circuit CBP45 (YE) for an open.
(YE) and ground. CLEAR the DTCs. REPEAT the self-test. TEST the
system for normal operation. If not OK, REFER to
the Wiring Diagrams manual to identify the possible
causes of the circuit short.

K3 CHECK CIRCUIT CH123 (VT/GN) FOR
AN OPEN
Yes K17
• Ignition OFF.
C2356a.
• Measure the resistance between blower
motor relay socket pin 2, circuit CH123
(VT/GN) and HVAC module - DATC
C2356a-24, circuit CH123 (VT/GN),
harness side.

.
No
REPAIR circuit CH123 (VT/GN) for an open. CLEAR the DTCs. REPEAT the self-test. TEST the system for
normal operation. K4 CHECK CIRCUIT VH101 (WH/VT) FOR AN OPEN
• Ignition OFF.
• Disconnect: HVAC Module - DATC C2356a.

• Measure the resistance between blower motor control C271-B, circuit VH101 (WH/VT), harness side
and HVAC module - DATC C2356a-14, circuit VH101 (WH/VT), harness side.
Yes
GO to K5 .
No
REPAIR circuit VH101 (WH/VT) for an open. CLEAR the DTCs. REPEAT the self-test. TEST the system
for normal operation. K5 CHECK CIRCUIT VH101 (WH/VT) FOR GROUND SIGNAL
• Connect: HVAC Module - DATC C2356a.

• Ignition ON.
• Press the PANEL button on the HVAC module. Adjust the blower motor setting to HI.
• Measure the voltage between blower motor speed control C271-B, circuit VH101 (WH/VT), harness
side and blower motor speed control C271-C, circuit CH402 (YE/GN), harness side.
Yes
GO to K16 .
No
GO to K17 . K6 CHECK FOR VOLTAGE TO THE BLOWER MOTOR
• Ignition OFF.
• Ignition ON.
• Measure the voltage between blower motor C288-A, circuit VH219 (GY), harness side and blower
motor C288-B, circuit VH301 (YE/BU), harness side.

Yes
INSTALL a new blower motor. TEST the system for normal operation.
No
GO to K7 . K7 CHECK FOR VOLTAGE TO THE BLOWER MOTOR CONTROLLER
• Ignition OFF.
• Ignition ON.
• Press the PANEL button on the HVAC module.
• Measure the voltage between blower motor speed control C271-C, circuit CH402 (YE/GN), harness
side and ground.
Yes
GO to K8 .
No
GO to K14 . K8 CHECK CIRCUIT GD115 (BK/GY) FOR AN OPEN
• Ignition OFF.
• Measure the resistance between blower motor speed control C271-A, circuit GD115 (BK/GY),
Yes
GO to K9 .

No
REPAIR circuit GD115 (BK/GY) for an open. TEST the system for normal operation. K9 CHECK
CIRCUIT VH101 (WH/VT) FOR GROUND SIGNAL
• Ignition ON.
• Press the PANEL button on the HVAC module. Adjust the blower motor setting to HI.
• Measure the voltage between blower motor speed control C271-B, circuit VH101 (WH/VT), harness
side and blower motor speed control C271-C, circuit CH402 (YE/GN), harness side.
Yes
GO to K10 .
No
GO to K17 . K10 CHECK CIRCUITS VH219 (GY) AND VH301 (YE/BU) FOR AN OPEN
• Measure the resistance between the blower motor connector, harness side and blower motor speed
control, harness side using the following chart.
Blower Motor Connector Circuit Blower Motor Speed Control Connector

C288-A VH219 (GY) C271-E
C288-B VH301 (YE/BU) C271-D
Yes
GO to K11 .
No
REPAIR circuit VH219 (GY) or VH301 (YE/BU) for an open. TEST the system for normal operation. K11
CHECK CIRCUITS VH219 (GY) AND VH301 (YE/BU) FOR A SHORT TOGETHER

• Measure the resistance between blower motor C288-A, circuit VH219 (GY), harness side and blower
motor C288-B, circuit VH301 (YE/BU), harness side.
Yes
GO to K12 .
No
REPAIR circuits VH219 (GY) and VH301 (YE/BU) for a short together. TEST the system for normal
operation. K12 CHECK CIRCUIT VH219 (GY) FOR A SHORT TO GROUND
• Measure the resistance between ground and blower motor C288-A, circuit VH219 (GY), harness side.
Yes
GO to K13 .
No
REPAIR circuit VH219 (GY) for a short to ground. TEST the system for normal operation. K13 CHECK
CIRCUIT VH301 (YE/BU) FOR A SHORT TO VOLTAGE
• Ignition ON.
• Measure the voltage between ground and blower motor C288-B, circuit VH301 (YE/BU), harness
side.

Yes
REPAIR circuit VH301 (YE/BU) for a short to voltage. TEST the system for normal operation.
No
GO to K16 . K14 CHECK THE RELAY SWITCH POWER CIRCUIT FOR AN OPEN
• Measure the voltage between blower motor relay socket pin 3, circuit SBB35 (BU/RD) and ground.
Yes
GO to K15 .
No
VERIFY Battery Junction Box (BJB) fuse 35 (40A) is OK. If OK, REPAIR circuit SBB35 (BU/RD) for an
open. TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams manual to identify
the possible causes of the circuit short. K15 CHECK THE MODULE OUTPUT
NOTICE: The following step uses a test light to simulate normal circuit loads. Use only the test
light recommended in the Special Tools table at the beginning of this section or equivalent. To
avoid connector terminal damage, use the Flex Probe Kit for the test light probe connection to
the vehicle. Do not use the test light probe directly on any connector.
• Ignition ON.
• With the engine running, connect a 12-volt test lamp between blower motor relay socket pin 2, circuit
CH123 (VT/GN) and socket pin 1, circuit CBP45 (YE).
Yes
CARRY OUT the blower motor relay component test.
Refer to Wiring Diagrams Cell 149 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ) for component testing.
If the relay tests OK, REPAIR circuit CH402 (YE/GN) for a short to ground. CLEAR the DTCs. REPEAT the
No

GO to K17 . K16 CHECK THE BLOWER MOTOR SPEED CONTROL CONNECTION
• Clear the DTCs.

• Disconnect the blower motor speed control connector.
• Check for:
♦ corrosion.
• Connect and correctly seat the connector.
• Carry out the HVAC On-Demand Self Test.
• Operate the system and verify the concern is still present.
Yes
INSTALL a new blower motor speed control. REFER to Section 412-01 . CLEAR the DTCs. TEST the
No
The system is operating correctly at this time. The concern may have been caused by a loose or corroded
connector. CLEAR the DTCs. TEST the system for normal operation. K17 CHECK THE MODULE
CONNECTION
• Inspect the module connectors for:

♦ corrosion.
• Clear the DTCs.
Yes
INSTALL a new HVAC module. REFER to Section 412-01 . TEST the system for normal operation.
No
connector. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
Pinpoint Test L: The Blower Motor Does Not Operate Correctly - DATC
Normal Operation
speed.

• DTC B10AF:14 (Blower Fan Relay: Circuit Short to Ground or Open) - The module senses no
• DTC B10B9:14 (Blower Control: Circuit Short to Ground or Open) - The module senses no voltage
on the blower motor control PWM circuit, indicating an open or a short directly round.

• Fuse(s)
• HVAC module - Dual Automatic Temperature Control (DATC)
PINPOINT TEST L: THE BLOWER MOTOR DOES NOT OPERATE CORRECTLY - DATC

L1 CHECK THE HVAC MODULE FOR DTCs
Yes
• Check the HVAC module for DTCs. (VT/GN) for a short to ground. CLEAR the
For DTC B10B9:14 , REPAIR circuit VH101

(WH/VT) for a short to ground. CLEAR the
No
GO to L2 .
L2 VERIFY THE BLOWER MOTOR
OPERATION
• Ignition ON. If the blower motor operates always in HI, GO

• Press the panel button on the HVAC module. to L4 .
Adjust the blower motor setting to LO and then
to HI. If the blower motor is always ON, CARRY
• Does the blower motor operate at any OUT the blower motor relay component test.
setting?
Fusion/MKZ , Fusion Hybrid/MKZ Hybrid )
If the relay tests OK, GO to L3 .
No
GO to Pinpoint Test K .
L3 CHECK CIRCUIT VH301 (YE/BU) FOR A
SHORT TO VOLTAGE
PINPOINT TEST L: THE BLOWER MOTOR DOES NOT OPERATE CORRECTLY - DATC 5009

• Disconnect: Blower Motor Speed Control REPAIR circuit VH301 (YE/BU) for a short to
C271. voltage. TEST the system for normal operation.
• Ignition ON. No
• Measure the voltage between ground and GO to L5 .
blower motor speed control C271-E, circuit
VH301 (YE/BU), harness side.

L4 CHECK CIRCUIT VH219 (GY) FOR A
SHORT TO GROUND
Yes
• Ignition OFF. INSTALL a new blower control. TEST the
• Measure the resistance between ground and system for normal operation. If the condition
blower motor speed control C271-D, circuit returns, GO to L5 .
VH219 (GY), harness side.
No
REPAIR circuit VH219 (GY) for a short to
voltage. TEST the system for normal operation.

L5 CHECK THE MODULE CONNECTION
Yes
• Operate the system and verify the concern is or corroded connector. CLEAR the DTCs.
still present. REPEAT the self-test. TEST the system for
Component Tests
Temperature Sensor - In-Vehicle
Ambient Temperature Resistance Between Pins 2 and 5

-40°C (-40°F) 869,073-1,061,986 ohms
-15°C (5°F) 196,465-231,213 ohms
0°C (32°F) 89,982-102,514 ohms
15°C (59°F) 44,261-49,503 ohms
25°C (77°F) 28,500-31,500 ohms
35°C (95°F) 18,563-20,751 ohms
60°C (140°F) 6,971-8,001 ohms
85°C (185°F) 2,959-3,474 ohms
Air Inlet Mode Door Actuator
Actuator PinsApprox. Resistance8 and 108,000-12,000 ohms8 and 91-10,000 ohms9 and 101-10,000
ohms51 and 671-85 ohms

SECTION 412-01: Climate Control
Manual
Item Specification
A/C Compressor
Oil
NOTICE: Use of
any A/C
compressor oil
other than what is
specified for the
specific vehicle
configuration will
damage the A/C
compressor and
contaminate the
refrigerant
system. For
non-hybrid
vehicles with a
pulley driven
(conventional)
A/C compressor,
PAG Refrigerant
Compressor Oil
only must be used.
For hybrid
vehicles with an
electric A/C
compressor,
Motorcraft®
Electric A/C
Compressor Oil
must be used.
Material

Motorcraft® Electric A/C - Hybrid vehicles
Compressor Oil only
YN-32 130 ml
(4.4 fl oz)
Motorcraft® PAG WSH-M1C231-B Non-hybrid
Refrigerant Compressor vehicles only 177
Oil ml
YN-12-D (6 fl oz)
Motorcraft® R-134a WSH-M17B19-A 0.62 kg

Refrigerant (22 oz)
YN-19 (US); CYN-16-R (1.38 lb)
(Canada)
Item Specification
Magnetic Clutch
Air gap between pulley and clutch disc 0.3-0.6 mm
(0.012-0.024 in)

A/C compressor bolts 25 18 -
A/C compressor bracket bolts 25 18 -
A/C compressor clutch disc and hub bolt 14 - 124
A/C compressor discharge fitting nut (hybrid) 15 133
A/C compressor manifold bolt 15 - 133
A/C compressor nut 25 18 -
A/C compressor stud 9 - 80
A/C compressor suction fitting nut (hybrid) 15 - 133
A/C pressure relief valve 10 - 89
A/C pressure transducer 10 - 89
Auxiliary coolant flow pump bracket bolts 25 18 -
Compressor manifold and tube suction fitting nut 15 - 133
Condenser fitting nut (inlet and outlet) 15 - 133
Condenser-to-evaporator line fitting nut 15 -
Evaporator outlet line fitting nut 15 - 133
Evaporator-to-compressor suction line bracket bolt 6 - 53
Heater core and evaporator core housing nuts 9 - 80
High-pressure Schrader-type valve 2.5 - 22
High-pressure service gauge port valve cap 0.8 - 7
Low-pressure Schrader-type valve 1.8 - 16
Low-pressure service gauge port valve cap 0.8 - 7
Radiator bracket bolts 10 - 89
Thermostatic Expansion Valve (TXV) fitting nut 15 - 133
manifold and tube bracket bolt 8 - 71
Washer reservoir filler neck bolt 6 - 53

Manual
Air Conditioning
The refrigerant system components include the following:
• Pulley-driven A/C compressor (non-hybrid)

• Electric A/C compressor (hybrid)
• A/C clutch assembly (non-hybrid)
• Receiver/drier cartridge
The refrigerant system incorporates an A/C compressor controlled by the PCM through an A/C clutch relay.
The HVAC module sends an A/C request signal to the Instrument Cluster (IC), which relays the request to the
PCM. An evaporator discharge air temperature sensor is used to disengage the A/C compressor clutch when
the evaporator core temperature falls below an acceptable temperature.
The A/C compressor clutch will only be engaged by the PCM if all of the following conditions are met:
• The HVAC module is set to a mode which provides an A/C request to the PCM via the IC .
• The evaporator discharge air temperature sensor is reading an acceptable temperature.
• The A/C pressure transducer is reading an acceptable pressure in the high side of the refrigerant
system.
• The A/C compressor relay is switched to the closed position by the PCM.
• The engine coolant temperature is not excessively high.
NOTE: To prevent erroneous readings that can result from underhood heat sources, the PCM uses data from
several sources to calculate ambient temperature. The vehicle must be driven for a sufficient time, speed and
distance after startup before the calculated ambient temperature is updated in the PCM. If a vehicle is moved
from a below-freezing environment to a warm environment (such as being moved from outside into a garage
or when delivered from a cold climate to a warm climate), the minimal amount of driving may not be
sufficient for the calculated ambient temperature to be updated. In this event, the PCM will believe the
ambient temperature is too low for A/C operation and, to prevent an increased risk of compressor slugging or
damage, will not engage the A/C compressor in any mode. To manually reset the PCM calculated ambient
temperature to the current temperature, run the vehicle until the thermostat opens and then clear the PCM
Keep Alive Memory (KAM). For the KAM resetting procedure, refer to Powertrain Control/Emissions
Diagnosis (PC/ED) manual. When the PCM KAM is reset, the ambient temperature will reset to the current
higher value (a value closer to actual surrounding conditions) and the A/C compressor will operate normally.
An A/C pressure relief valve is installed in the A/C compressor to protect the refrigerant system against
excessively high refrigerant pressures.
Refrigerant flow into the evaporator core is metered by a TXV .
A/C Compressor and Clutch Assembly - Non-Hybrid
Air Conditioning 5015

NOTE: Internal A/C compressor components are not serviced separately. The A/C compressor is serviced
only as an assembly. The clutch disc and hub, A/C compressor pulley and bearing and clutch field coil are
serviceable.
The A/C compressor has the following characteristics:
• A non-serviceable shaft seal

• A pressure relief valve is installed in the rear of the compressor to protect the refrigerant system
against excessively high refrigerant pressures
• The A/C compressor uses PAG oil or equivalent. This oil contains special additives required for the
A/C compressor
• The A/C compressor oil may have some slightly dark-colored streaks while maintaining normal oil
viscosity. This is normal for this A/C compressor because of break-in wear that can discolor the oil
• Use standard oil matching procedures when installing new compressors

1 W712303 A/C clutch disc and hub bolt
2 19D786 A/C clutch disc and hub
3 19D648 A/C clutch disc and hub spacers
4 W712302 A/C compressor pulley snap ring
5 19D784 A/C compressor pulley
6 W712301 A/C clutch field coil snap ring
7 1998 A/C clutch field coil
When battery voltage is applied to the A/C compressor clutch field coil, the clutch plate and hub assembly is
drawn toward the A/C clutch pulley. The magnetic force locks the clutch plate and hub assembly and the A/C
clutch pulley together as one unit, causing the compressor shaft to rotate. When battery voltage is removed
from the A/C compressor clutch field coil, springs in the clutch plate and hub assembly move the clutch plate
away from the A/C clutch pulley.
Electric A/C Compressor - Hybrid
NOTICE: Motorcraft® Electric Compressor Oil YN-32 only must be used as a refrigerant system
lubricant for hybrid vehicles. Addition of any oil other than Motorcraft® Electric Compressor Oil
YN-32 to the refrigerant system will damage the electric Air Conditioning (A/C) compressor and
contaminate the refrigerant system. For the Refrigerant Oil Adding procedure, refer to Section
412-00A .
Hybrid vehicles are equipped with a variable-speed electric A/C compressor that is powered by the
high-voltage traction battery system. The electric A/C compressor allows for A/C operation to continue even
when the vehicle is in full electric mode and the gasoline engine is not running. The Air Conditioning
Compressor Module (ACCM) is an integral part of the electric A/C compressor and cannot be removed from
the compressor.

A/C Pressure Relief Valve
NOTE: If the A/C compressor is operating within limits and the A/C pressure relief valve is venting, or if the
A/C pressrelief valve is leaking around the threads, replace the A/C pressure relief valve and O-ring. If the
A/C pressure relief valve still vents after it is replaced, diagnose the refrigerant system for a restriction.
An A/C pressure relief valve is incorporated in the A/C compressor to prevent damage to the A/C compressor
and other system components by relieving unusually high system discharge pressure buildups. For
specifications regarding operating pressure(s), refer to Section 412-00A .
The A/C pressure relief valve is a separate component and can be replaced separately from the A/C
compressor. It is necessary to recover the refrigerant before removing the A/C pressure relief valve.
A/C Condenser
The A/C condenser is an aluminum fin-and-tube design heat exchanger located in front of the vehicle radiator.
It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and by
condensing gas to liquid refrigerant as it is cooled.
The receiver/drier is incorporated onto the LH side of the condenser core. The receiver/drier (desiccant)
cartridge is a separate component and can be removed and installed separately from the condenser core.
On 3.5L vehicles only, the top portion of the condenser/power steering combo cooler is partitioned from the
refrigerant system and is used for power steering fluid cooling.
Receiver/Drier Cartridge
NOTE: Installation of a new receiver/drier cartridge is not required when repairing the A/C system, except
when there is physical evidence of contamination from a failed A/C compressor or damage to the
receiver/drier cartridge. Damage to the receiver/drier cartridge includes physical damage or moisture
contamination. Moisture contamination results only from a complete loss of refrigerant, and equalization of
the refrigerant system pressure with atmospheric pressure for a period longer than one hour. If even a slight
amount of positive refrigerant pressure is present in the refrigerant system before repairs are carried out, the
receiver/drier cartridge does not need to be replaced.
The receiver/drier is integral to the A/C condenser. It stores high-pressure liquid after it leaves the condenser
core. A receiver/drier (desiccant) cartridge mounted inside the receiver/drier removes any retained moisture
from the refrigerant. The receiver/drier cartridge is a separate component and can be removed and installed
separately from the A/C condenser.
Evaporator Core
The evaporator core is an aluminum plate/fin type and is located in the heater core and evaporator core
housing. A mixture of refrigerant and oil enters the bottom of the evaporator core through the evaporator core
inlet tube and continues out of the evaporator core through the evaporator core outlet tube as a vapor. Air from
the blower motor is cooled and dehumidified as it flows through the evaporator core fins.
Thermostatic Expansion Valve (TXV)
The TXV is located between the evaporator core inlet and outlet tubes and the TXV manifold and tube

assembly at the rear of the engine compartment. The TXV provides a restriction to the flow of refrigerant
from the high-pressure side of the refrigerant system and separates the low-pressure and high-pressure sides of
the refrigerant system. Refrigerant entering and exiting the evaporator core passes through the TXV through 2
separate flow paths. An internal temperature sensing bulb senses the temperature of the refrigerant flowing out
of the evaporator core and adjusts an internal pin-type valve to meter the refrigerant flow into the evaporator
core. The internal pin-type valve decreases the amount of refrigerant entering the evaporator core at lower
temperatures and increases the amount of refrigerant entering the evaporator core at higher temperatures.
The evaporator discharge air temperature sensor contains a thermistor which receives a reference voltage from
the PCM. The thermistor then varies the resistance to the reference voltage based on the evaporator discharge
air temperature. The resulting voltage is returned to the PCM where it is interpreted as an evaporator
discharge air temperature reading.
The PCM maintains evaporator core temperature and prevents icing of the evaporator core, by disengaging the
A/C compressor clutch (non-hybrid) or decreasing the electric A/C compressor speed (hybrid) when the
evaporator discharge air temperature sensor reading falls below acceptable levels, and by engaging the A/C
compressor clutch (non-hybrid) or increasing the electric A/C compressor speed (hybrid) when the discharge
air temperature rises above acceptable levels.
The evaporator discharge air temperature sensor is located inside of the heater core and evaporator core
housing in the air-stream leaving the evaporator core.
A/C Pressure Transducer
The A/C pressure transducer monitors the compressor discharge pressure and sends a variable voltage signal
representing the pressure to the PCM. The PCM will interrupt A/C compressor operation (non-hybrid), or
decrease the electric A/C compressor speed (hybrid) in the event that the A/C pressure transducer indicates
high system discharge pressures. It is also used to sense low charge conditions. If the pressure is below a
predetermined value for a given ambient temperature, the PCM will not allow the A/C compressor to operate.
The A/C pressure transducer is located on the high-pressure side of the TXV manifold and tube assembly near
the TXV fitting.
Service Gauge Port Valves
The high-pressure service gauge port valve is located on the condenser-to-evaporator line.
The low-pressure service gauge port valve is located on the TXV manifold and tube assembly.


1 19D702 Low-pressure service gauge port valve cap
2 - Low-pressure service gauge port valve
3 19D701 Low-pressure Schrader-type valve
4 19D701 High-pressure Schrader-type valve
5 - High-pressure service gauge port valve
6 19D702 High-pressure service gauge port valve cap
The fitting is an integral part of the refrigeration line or component.
• Special couplings are required for both the high-side and low-side service gauge ports.
• A very small amount of leakage will always be detectable around the Schrader-type valve with the
service gauge port valve cap removed, and is considered normal. A new Schrader-type valve core can
be installed if the seal leaks excessively.
• The service gauge port valve caps are used as primary seals in the refrigerant system to prevent
leakage through the Schrader-type valves from reaching the atmosphere. Always install and tighten
the A/C service gauge port valve caps to the correct torque after they are removed.
Refrigerant System Dye
NOTICE: Fluorescent refrigerant system dye mixed with PAG oil should never be added to hybrid
vehicle Air Conditioning (A/C) systems equipped with an electric A/C compressor. Addition of
fluorescent refrigerant system dye containing PAG oil will damage the electric A/C compressor and
contaminate the refrigerant system.
Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant
system leak diagnosis using a Rotunda-approved UV blacklight. It is not necessary to add additional dy the
refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from
the system. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system
lubricant capacity has been lost due to a fitting separation or hose rupture. Refer to Section 412-00A .
For hybrid vehicles equipped with an electric compressor, additional refrigerant system dye should only be
added by installing a new receiver/drier cartridge. Replacement receiver/drier cartridges include a fluorescent
dye "wafer" which will dissolve after approximately one hour of continued A/C operation. Fluorescent
refrigerant system dye mixed with PAG oil should never be used in hybrid vehicles with an electric A/C
compressor.



Manual
Air Distribution and Filtering
NOTE: This vehicle is equipped from the factory with a cabin air filter. For filter maintenance intervals, refer
to Section 100-03 .
There are 2 sources of air available to the air distribution system:
• Outside air
• Recirculated air
Recirculated air is always used when the HVAC module is set to the MAX A/C mode on vehicles equipped
with Electronic Manual Temperature Control (EMTC). Vehicles equipped with Electronic Automatic
Temperature Control (EATC) use recirculated air when the RECIRC function is selected in any mode other
than DEFROST, or when required by the HVAC module in the AUTOMATIC mode. On hybrid vehicles
only, the air inlet door may stop in a mid-position if required for increased cooling performance as determined
by the HVAC module.
Air distribution within the vehicle is determined by the EMTC system settings or the EATC system in the
AUTOMATIC mode. The air distribution mode on vehicles equipped with EATC can be overridden by the
driver if desired. Airflow mode control doors are used to direct airflow within the heater core and evaporator
core housing. Electric mode door actuators are used to position these airflow mode doors.
NOTE: For the passenger side temperature setting on hybrid vehicles equipped with a dual-zone Electronic
Vehicles equipped with dual-zone EATC use 2 separate temperature blend doors. This allows individual
temperature settings to be selected for the RH and LH air outlets. The airflow mode doors are not partitioned
for separate RH and LH airflow positions. Therefore, the airflow mode will always remain similar for the RH
and LH sides of the vehicle regardless of the temperatures selected.
Air enters the passenger compartment from the:
• instrument panel registers.

• floor duct.
• windshield defroster.
• side window demisters.
• rear footwell duct.
Passenger compartment air is exhausted from the vehicle through open windows or body air vents.
Air Distribution and Filtering 5021

Air Distribution and Filtering 5022


Manual
Control Components
Electronic Manual Temperature Control (EMTC)
The Electronic Manual Temperature Control (EMTC) components are used to select:
• air inlet source (outside or recirculated).

• blower motor speed.
• discharge air temperature (temperature blend).
• discharge air location (defrost, panel, floor).
• A/C compressor operation.
Control System Inputs
HVAC Module
The HVAC module integrates the temperature control, blower motor switch, airflow mode selection, A/C
request button, recirculated air request button and rear defog switch into a single unit.
The temperature control switch setting determines air temperature. Movement of the temperature display from
COOL (blue) to WARM (red) causes a corresponding movement of the temperature blend door and
determines the air discharge temperature that the air distribution system will maintain. The temperature
control switch is an integral part of the HVAC module and cannot be installed separately.
The blower motor speed switch is mounted in the HVAC module and controls blower motor speed by adding
or bypassing resistors in the blower motor resistor in all modes except OFF. The blower motor speed switch is
an integral part of the HVAC module and cannot be installed separately.
The airflow mode setting determines air discharge location. Depressing each airflow mode selector button
causes a corresponding movement of the airflow mode doors and determines the air discharge location. The
airflow mode selector buttons are an integral part of the HVAC module and cannot be installed separately.
The A/C request button determines A/C compressor operation, except when the function selected is OFF,
MAX or DEFROST. The A/C request button is an integral part of the HVAC module and cannot be installed
separately.
The recirculated air request button can select recirculated air in any mode except DEFROST, and fresh air in
any mode except MAX A/C or OFF.
The rear defog button signals activation of the heated backlight. The rear defog button is an integral part of the
HVAC module and cannot be installed separately.
Control System Outputs
The EMTC system has 3 system outputs.
Control Components 5023

Blower Motor Speed
The blower motor speed switch varies the blower motor ground circuit resistance by adding or bypassing
series resistance in the blower motor resistor. Increased resistance will lower the blower motor speed, and
lowered resistance will increase blower motor speed. When the blower motor is in the HI (4) position, the
blower motor resistor is bypassed.
The blower motor resistor is located on the heater core and evaporator core housing near the blower motor.
Temperature Blend Door Position
The temperature blend door actuator moves the temperature blend door on command from the HVAC module.
The temperature blend door actuator contains a reversible electric motor and a potentiometer. The
potentiometer circuit consists of a 5-volt reference signal connected to one end of a variable resistor, and a
signal ground connected to the other. A signal circuit is connected to a contact wiper, which is driven along
the variable resistor by the actuator shaft. The signal to the HVAC module from the contact wiper indicates
the position of the temperature blend door. The HVAC module powers the actuator motor to move the
temperature blend door to the desired position. The desired position is set by the vehicle occupants using the
temperature selector knob.
Airflow Mode Door Position
The airflow mode door actuator uses a cam and lever assembly to position the airflow mode doors on
command from the HVAC module. The mode door actuator contains a reversible electric motor and
potentiometer. The potentiometer allows the HVAC module to monitor the position of the airflow mode
doors. The potentiometer circuit consists of a 5-volt reference signal connected to one end of a variable
resistor, and a signal ground connected to the other. A signal circuit is connected to a contact wiper, which is
driven along the variable resistor by the actuator shaft. The signal to the HVAC module from the contact
wiper indicates the position of the airflow mode doors. The HVAC module powers the actuator motor to move
the airflow mode doors to the desired position. The desired position is set by the vehicle occupants using the
mode selector buttons.
The airflow (defrost/panel/floor) mode door actuator is located on the heater core and evaporator core housing
to the right of the steering column.
Air Inlet Mode Door Position
The air inlet mode door actuator moves the air inlet door between the fresh and RECIRC positions on
command from the HVAC module. The air inlet mode door actuator is driven to, and will automatically stop
at, the full RECIRC or full fresh air inlet position and does not require a potentiometer circuit to monitor its
position. The air inlet mode door does not stop at any point between the RECIRC or fresh air inlet position.
The air inlet mode door actuator is located on the air inlet duct near the RH cowl side panel.
Electronic Automatic Temperature Control (EATC)
The HVAC module analyzes input from the following major sources:
• Temperature, airflow direction, blower, A/C and RECIRC selection (made by the vehicle occupants)
• In-vehicle temperature sensor (non-hybrid)
• In-vehicle temperature and humidity sensor (hybrid)
• Solar radiation sensor (sunload sensor)
Blower Motor Speed 5024

• Vehicle speed
• Engine coolant temperature
• Occupant Classification Sensor (OCS) (hybrid only)
Using these inputs, the HVAC module determines the correct conditions for the following outputs:
• A/C compressor operation

• Blower motor speed
• RH and LH temperature blend door positions
• DEFROST/PANEL/FLOOR airflow mode door position
• Air inlet mode door position
Control System Inputs
The EATC system has 4 control system inputs.
HVAC Module - Without Navigation System
The HVAC module on vehicles not equipped with the navigation system provides an interface for the vehicle
occupants to control the climate control system, or automatically controls the system in the AUTO mode. The
Front Display Interface Module (FDIM) displays set temperature, airflow direction and blower speed.
The HVAC module is mounted to the center instrument panel finish panel below the Front Controls Interface
Module (FCIM).
HVAC Module - With Navigation System
Vehicles equipped with the navigation system use a remote HVAC module that is separate from the control
interface. The FCIM provides the interface for the vehicle occupants to control the climate control system.
When selections are made, the FCIM communicates the selections to the HVAC module over the Medium
Speed Controller Area Network (MS-CAN). The remote HVAC module controls the climate control system
based on the FCIM selections or will automatically control the climate control system in the AUTO mode.
The HVAC module is mounted to the instrument panel support behind the FCIM .
In-Vehicle Temperature Sensor - Non-Hybrid
The in-vehicle temperature sensor contains a thermistor, which measures the in-vehicle air temperature and
sends that reading to the HVAC module. An aspirator hose is connected between the heater core and
evaporate housing and the in-vehicle temperature sensor. The aspirator hose uses airflow through the heater
core and evaporator core housing to create a Venturi-type suction in the hose to draw in-vehicle air through
the in-vehicle temperature sensor (across the thermistor).
The in-vehicle temperature sensor is mounted to the instrument panel to the right of the steering column with
the aspirator hose connected to the heater core and evaporator core housing near the LH temperature blend
door actuator.
In-Vehicle Temperature and Humidity Sensor - Hybrid
The in-vehicle temperature and humidity sensor contains 2 thermistors, which separately measure the
in-vehicle air temperature and humidity and send those readings to the HVAC module. The in-vehicle
temperature sensor has an integral electric fan within the sensor that draws in-vehicle air across the
thermistors.
Air Inlet Mode Door Position 5025

The in-vehicle temperature and humidity sensor is mounted to the instrument panel to the right of the steering
column.
Solar Radiation Sensor (Sunload Sensor)
The solar radiation sensor supplies information to the HVAC module indicating sunload.
Ambient Temperature Sensor
The ambient temperature sensor signal is received by the HVAC module and indicates the outside air
temperature. The ambient temperature sensor is located in front of the radiator on the radiator support.
Control System Outputs
The EATC system has 3 control system outputs.
NOTE: For the passenger side temperature setting on hybrid vehicles equipped with a dual-zone Electronic
4/08/2009 to be functional, a passenger must be seated in the front passenger seat. If the frontassenger seat is
not occupied, the HVAC module will control the system based only on the driver side temperature setting.
Blower Motor Speed
The blower motor speed control controls the blower motor speed by converting low power signals from the
HVAC module to a high-current, variable ground feed for the blower motor. The HVAC module adjusts
blower motor speed based on the difference between the in-vehicle temperature sensor signal and set
temperature. A delay function is used to provide a gradual increase or decrease in blower motor speed under
all conditions.
The blower motor speed control is located on the heater core and evaporator core housing near the blower
motor.
Temperature Blend Door Positions
The dual-zone EATC system uses 2 temperature blend door actuators to control 2 separate temperature blend
doors. The temperature blend doors independently vary the LH side and RH side temperature settings, as
desired. The temperature blend door actuators each contain a reversible electric motor and a potentiometer.
The potentiometer circuit consists of a 5-volt reference signal connected to one end of a variable resistor, and
a signal ground connected to the other. A signal circuit is connected to a contact wiper, which is driven along
the position of the temperature blend door. The HVAC module powers the actuator motors to move the
temperature blend doors to the desired positions. The desired temperature blend door positions are calculated
by the HVAC module based on the set temperature, in-vehicle temperature, ambient temperature and sunload.
The LH temperature blend door actuator is located on the heater core and evaporator core housing near the
accelerator pedal. The RH temperature blend door actuator is located on the heater core and evaporator core
housing to the left of the glove compartment.
Airflow Mode Door Position
The airflow mode door actuator uses a cam and lever assembly to position the airflow mode doors on
command from the HVAC module. The mode door actuator contains a reversible electric motor and
In-Vehicle Temperature and Humidity Sensor - Hybrid 5026

potentiometer. The potentiometer allows the HVAC module to monitor the position of the airflow mode
doors. The potentiometer circuit consists of a 5-volt reference signal connected to one end of a variable
resistor, and a signal ground connected to the other. A signal circuit is connected to a contact wiper, which is
driven along the variable resistor by the actuator shaft. The signal to the HVAC module from the contact
wiper indicates the position of the airflow mode doors. The HVAC module powers the actuator motor to move
the airflow mode doors to the desired position. The HVAC module determines the desired airflow mode door
position based on the calculated outlet temperature.
The airflow mode door actuator is located on the heater core and evaporator core housing to the right of the
accelerator pedal.
Air Inlet Mode Door Actuator - Non-hybrid
command from the HVAC module. The air inlet mode door actuator is driven to, and will automatically stop
at, the full RECIRC or full fresh air inlet position and does not require a potentiometer circuit to monitor its
position. The air inlet mode door does not stop at any point between the RECIRC or fresh air inlet position.
The air inlet mode door actuator is located on the airnlet duct near the RH cowl side panel.
Air Inlet Mode Door Actuator - Hybrid
command from the HVAC module. The airflow mode door actuator contains a reversible electric motor and
potentiometer. The potentiometer allows the HVAC module to monitor the position of the air inlet mode door.
The potentiometer circuit consists of a 5-volt reference signal connected to one end of a variable resistor, and
a signal ground connected to the other. A signal circuit is connected to a contact wiper, which is driven along
the position of the air inlet mode door. The HVAC module powers the actuator motor to move the air inlet
mode door to the desired position. The HVAC module determines the desired air inlet mode door position
based on the calculated outlet temperature.
The air inlet mode door actuator is located on the air inlet duct near the RH cowl side panel.
Airflow Mode Door Position 5027


Manual
Heating and Ventilation
The heating and ventilation system has the following features:
• Controls the temperature and, during A/C operation, reduces the relative humidity of the air inside the
vehicle
• Delivers heated or cooled air to maintain the vehicle interior temperature and comfort level
• Cooling or heating can be adjusted to maintain the desired temperature
• Uses a reheat method to provide conditioned air to the passenger compartment
• All airflow from the blower motor passes through the A/C evaporator core
• Temperature blending is controlled by the temperature blend door(s), which regulate(s) the amount of
air that flows through and around the heater core, where it is then mixed and distributed
Heater Core
The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer the
heat to air passing through the plenum.
Blower Motor
The blower motor pulls air from the air inlet and forces it into the heater core and evaporator core housing
where it is mixed and distributed.
Heater Core and Evaporator Core Housing
The heater core and evaporator core housing directs airflow from the blower motor through the evaporator
core and heater core. All airflow from the blower motor passes through the evaporator core. The airflow is
then directed through or around the heater core by the temperature blend door(s). Vehicles equipped with
dual-zone Electronic Automatic Temperature Control (EATC) use a partitioned heater core and evaporator
core housing with 2 electric actuator-positioned temperature blend doors. This allows for separate
temperatures to be selected for the driver and passenger sides of the passenger compartment. Manual systems
and single-zone EATC systems use a single electric actuator-positioned temperature blend door to direct
airflow through or around the heater core.
An auxiliary coolant flow pump is used only on hybrid vehicles to improve engine coolant circulation at low
engine speeds or when the engine is OFF.

Air Inlet Mode Door Actuator - Hybrid 5028

When none of the listed conditions are present, the auxiliary coolant flow pump is controlled by a strategy
included in the PCM software. The control strategy monitors the ambient temperature, coolant temperature
and engine rpm. As the ambient temperature and/or coolant temperature increase, the auxiliary coolant flow
pump will shut down at lower engine speeds. For example, when both the ambient temperature is above 16°C
(60°F) and the engine coolant temperature is above 66°C (150°F), the control strategy will shut off the
auxiliary coolant flow pump at 2,000 rpm. When both the ambient temperature is above 24°C (75°F) and the
engine coolant temperature is above 66°C (150°F), the control strategy will shut off the auxiliary coolant flow
pump regardless of engine speed.
To verify auxiliary coolant flow pump operation, allow the vehicle to cool in a cool location. Start the engine
and let the engine idle until it shuts down automatically. Select the FLOOR mode on the HVAC module at the
highest temperature setting and HI blower speed. If the auxiliary coolant flow pump is inoperative or is not
producing adequate coolant flow, the passenger compartment air discharge temperature will quickly decrease
and further diagnosis is required. Refer to Section 412-00B . If the auxiliary coolant flow pump is operating
normally, the passenger compartment air discharge temperature will remain steady, or slowly decrease.
Heating and Ventilation 5029


Manual
REMOVAL AND
INSTALLATION
Air Conditioning (A/C) Compressor - 2.5L
Material
Item Specification
Motorcraft® PAG Refrigerant WSH-M1C231-B
Compressor Oil
YN-12-D

1 - Field coil electrical connector (part of 12B637)
2 W701625 A/C compressor manifold bolt
3 W711824 A/C compressor bolt (3 required)
4 19703 A/C compressor
5 19B596 Gasket seal (2 pieces from kit required)
NOTICE: If installing a new Air Conditioning (A/C) compressor due to an internal failure of the old
unit, the following procedures must be carried out to remove contamination from the A/C system.
Failure to remove contamination from the A/C system, if present, will result in poor A/C performance
and/or damage to the new A/C compressor and other components.
• If A/C flushing equipment is available, carry out flushing of the A/C system prior to installing a new
A/C compressor. For additional information, refer to Section 412-00A .
• If A/C flushing equipment is not available, carry out filtering of the A/C system after a new A/C
compressor has been installed. For additional information, refer to Section 412-00A .
• Install a new Thermostatic Expansion Valve (TXV), as directed by the A/C flushing or filtering
procedure.
• Install a new receiver/drier cartridge as directed by the A/C flushing or filtering procedure.
NOTICE: Use only the Air Conditioning (A/C) refrigerant compressor oil specified for this vehicle
configuration. Use of any A/C refrigerant compressor oil other than what is specified will contaminate
Air Conditioning (A/C) Compressor - 2.5L 5030

and damage the A/C system.
1. If flushing of the A/C system has not been carried out, recover the refrigerant. For additional
100-02 .
3. Disconnect the field coil electrical connector.
4. Remove the A/C compressor manifold bolt.

• Discard the gasket seals.
5. Remove the drive belt from the A/C compressor pulley.
6. Remove the 3 A/C compressor bolts.

7. Remove the A/C compressor.

• Install new gasket seals.
• If filtering of the A/C system is not to be carried out, add the correct amount of clean PAG oil
to the refrigerant system. For additional information, refer to the Refrigerant Oil Adding
procedure in Section 412-00A .
9. If filtering of the A/C system is not to be carried out, evacuate, leak test and charge the refrigerant
system. For additional information, refer to Section 412-00A .



Manual
REMOVAL AND
INSTALLATION
Air Conditioning (A/C) Compressor - 3.0L, 3.5L
Material
Item Specification
Compressor Oil
YN-12-D
NOTE: 3.0L shown, 3.5L similar.
Part
1 W701625 A/C compressor manifold bolt
2 - Field coil electrical connector (part of 12B637)
3 W710649 A/C compressor bolt (3 required for 3.0L) (2 required
for 3.5L)
• If A/C flushing equipment is available, carry out flushing of the A/C system prior to installing a new
A/C compressoadditional information, refer to Section 412-00A .
Air Conditioning (A/C) Compressor - 3.0L, 3.5L 5033

procedure.
All vehicles
1. If flushing of the A/C system has not been carried out, recover the refrigerant. For additional
100-02 .
3. Remove the lower engine splash shield (if equipped).
4. Remove the drive belt from the A/C compressor pulley.
5. Remove the A/C compressor manifold bolt.

6. Disconnect the field coil electrical connector.
3.0L vehicles

3.5L vehicles

9. Remove the A/C compressor stud.

1. Remove the A/C compressor nut.
2. Remove the A/C compressor stud.
♦ To install, tighten the stud to 9 Nm (80 lb-in).
♦ To install, tighten the nut to 25 Nm (18 lb-ft).

All vehicles

• If filtering of the A/C system is not to be carried out, add the correct amount of clean PAG oil
12. If filtering of the A/C system is not to be carried out, evacuate, leak test and charge the refrigerant
system. For additional information, refer to Section 412-00A .


Manual
REMOVAL AND
INSTALLATION
Air Conditioning (A/C) Compressor - Hybrid
Material
Item Specification
Motorcraft® Electric A/C Compressor -
Oil
YN-32

1 - A/C compressor electrical connector (part of 14290)
2 W520413 A/C compressor suction fitting nut
3 W701626 Lower rear A/C compressor bolt
4 W520413 A/C compressor discharge fitting nut
5 W701626 Upper A/C compressor bolt
6 W500320 A/C compressor bracket bolt (2 required)
7 W701626 Lower front A/C compressor bolt
9 19B596 O-ring seal and gasket seal kit
lubricant for hybrid vehition of any oil other than Motorcraft® Electric A/C Compressor Oil to the
Air Conditioning (A/C) Compressor - Hybrid 5036

hybrid vehicle refrigerant system will damage the electric Air Conditioning (A/C) compressor and
contaminate the refrigerant system. Refer to the Refrigerant Oil Adding procedure in Section 412-00A .
NOTICE: Service electric Air Conditioning (A/C) compressors are shipped with a small amount of
electric compressor oil already installed which may not match the nominal amount required by the
refrigerant system. Before installing a new service electric A/C compressor, the correct electric
compressor oil level must be determined based on the amount of oil removed along with the old electric
A/C compressor. Refer to the Refrigerant Oil Adding procedure in Section 412-00A . Failure to
correctly match the electric compressor oil amount will result in damage to the electric A/C compressor
and other refrigerant system components.
• If A/C flushing equipment is available, cary out flushing of the A/C system prior to installing a new
A/C compressor. For additional information, refer to Section 412-00A .
procedure.
100-02 .
2. Depower the high-voltage traction battery system. For additional information, refer to Section 414-03
.
3. Recover the refrigerant. For additional information, refer to Section 412-00A .
4. NOTICE: Failure to disconnect high-voltage cable connectors as instructed may result in

damage to the connectors.
Release the clips and locking tabs and disconnect the interlock connector and the high-voltage cable
connector at the Air Conditioning Compressor Module (ACCM).
• Press the locking clip in the white interlock connector and disengage the white connector
before releasing the locking clip on the orange portion of the high-voltage connector. The
white interlock connector will not come completely apart until the orange portion is released.

5. Detach the A/C compressor high-voltage electrical connector pin-type retainer and reposition the
compressor high-voltage electrical connector below the coolant hoses.
6. Remove the condenser inlet fitting nut and disconnect the fitting.
7. Disconnect the A/C compressor electrical connector.
8. Remove the A/C compressor suction fitting nut and disconnect the fitting.
9. Detach the wire harness pin-type retainers from the vacuum pump bracket and A/C compressor
bracket.
10. Detach the wire harness pin-type retainer from the front subframe.
11. Remove the lower rear A/C compressor bolt.

12. Remove the A/C compressor discharge fitting nut and remove the compressor-to-condenser discharge
line.
• Discard the O-ring seal and gasket seal.
13. Remove the upper A/C compressor bolt.

14. Remove the 2 A/C compressor bracket bolts and remove the A/C compressor bracket.
15. Remove the lower front A/C compressor bolt.

Conditioning (A/C) compressor and contaminate the refrigerant system. Refer to the
Refrigerant Oil Adding procedure in Section 412-00A .
• Install new O-ring seals and gasket seals.

• Add the correct amount of clean electric A/C compressor oil to the refrigerant system. For
additional information, refer to the Refrigerant Oil Adding procedure in Section 412-00A .
18. Evacuate, leak test and charge the refrigerant system. For additional information, refer to Section
412-00A .


Manual
REMOVAL AND
INSTALLATION
Air Conditioning (A/C) Evaporator Discharge Air Temperature Sensor
Part
1 - A/C evaporator discharge air temperature sensor
electrical connector (part of 19D887)
2 19C734 A/C evaporator discharge air temperature sensor
1. Remove the instrument panel. For additional information, refer to Section 501-12 .
2. Rotate the A/C evaporator discharge air temperature sensor counterclockwise and pull upward to
detach it from the heater core and evaporator core housing.
3. Disconnect the A/C evaporator discharge air temperature sensor electrical connector.
4. Remove the evaporator discharge air temperature sensor.
Air Conditioning (A/C) Evaporator Discharge Air Temperature Sensor 5040

Air Conditioning (A/C) Evaporator Discharge Air Temperature Sensor 5041


Manual
REMOVAL AND
INSTALLATION
Air Conditioning (A/C) Pressure Transducer
Part
1 - A/C pressure transducer electrical connector (part of
14290)
2 19D594 A/C pressure transducer
3 19E889 O-ring seal
1. Disconnect the A/C pressure transducer electrical connector.
2. Remove the A/C pressure transducer.


• Install a new O-ring seal.
Air Conditioning (A/C) Pressure Transducer 5042

Air Conditioning (A/C) Pressure Transducer 5043


Manual
REMOVAL AND
INSTALLATION
Air Conditioning (A/C) Pressure Relief Valve
Material
Item Specification
Compressor Oil
YN-12-D

1 19D644 A/C pressure relief valve
2 - O-ring seal (part of 19D644)
100-02 .
3. Remove the A/C pressure relief valve and O-ring seal.

4. NOTE: A new O-ring seal will already be installed on the new A/C pressure relief valve service part.
• Add the correct amount of clean PAG refrigerant oil to the refrigerant system. For additional
412-00A .
Air Conditioning (A/C) Pressure Relief Valve 5044

Air Conditioning (A/C) Pressure Relief Valve 5045


Manual
REMOVAL AND
INSTALLATION
Ambient Air Temperature Sensor
Part
1 W709976 Lower radiator air deflector front screw (4 required)
2 N807389 Lower radiator air deflector pin-type retainer (4
required)
3 W706805 Lower radiator air deflector rear screw (2 required)
4 8327 Lower radiator air deflector
5 - Ambient air temperature sensor electrical connector
(part of 14290)
6 19E642 Ambient air temperature sensor
1. Remove the 4 lower radiator air deflector front screws.
2. Remove the 4 lower radiator air deflector pin-type retainers.
3. Remove the 2 lower radiator air deflector rear screws.
4. Remove the lower radiator air deflector.
5. Detach and disconnect the ambient air temperature sensor electrical connector.
6. Remove the ambient air temperature sensor.
Ambient Air Temperature Sensor 5046

Ambient Air Temperature Sensor 5047


Manual
REMOVAL AND
INSTALLATION
Part
1 W500233 Auxiliary coolant flow pump bracket bolt (3 required)
2 - Auxiliary coolant flow pump electrical connector (part
of 19D649)
3 8287 Heater hose clamp (2 required)
4 18D473 Auxiliary coolant flow pump
1. Drain the engine coolant. For additional information, refer to Section 303-03B .
2. Remove the 3 auxiliary coolant flow pump bolts.

3. Disconnect the auxiliary coolant flow pump electrical connector.
4. Release the 2 heater hose clamps and disconnect the 2 heater hoses from the auxiliary coolant flow
pump.
5. Remove the auxiliary coolant flow pump.
7. Fill the engine coolant level. For additional information, refer to Section 303-03B .
Auxiliary Coolant Flow Pump 5048

Auxiliary Coolant Flow Pump 5049


Manual
REMOVAL AND
INSTALLATION
Blower Motor

1 - Blower motor electrical connector (part of 19D887)
2 W712320 Blower motor screw (3 required)
3 19805 Blower motor
MKZ vehicles
1. Remove the RH lower instrument panel insulator.
All vehicles
2. Disconnect the blower motor electrical connector.
3. Remove the 3 blower motor screws.
4. Remove the blower motor.
Blower Motor 5050

Blower Motor 5051


Manual
REMOVAL AND
INSTALLATION
Blower Motor Resistor
Part
1 - Blower motor resistor electrical connector (part of
19D887)
2 - Blower motor resistor screw
3 18591 Blower motor resistor
1. Disconnect the blower motor resistor electrical connector.
2. Remove the blower motor resistor screw.
3. Remove the blower motor resistor.
Blower Motor Resistor 5052


Manual
REMOVAL AND
INSTALLATION
Blower Motor Speed Control
Part
1 - Blower motor speed control electrical connector (part of
19D887)
2 - Blower motor speed control screw
3 19E624 Blower motor speed control
MKZ vehicles
1. Remove the RH lower instrument panel insulator.
All vehicles
2. Disconnect the blower motor speed control electrical connector.
3. Remove the blower motor speed control screw.
4. Remove the blower motor speed control.
Blower Motor Speed Control 5053

Blower Motor Speed Control 5054


Manual
REMOVAL AND
INSTALLATION
Cabin Air Filter

1 99020C34 Cabin air filter access door
2 19N619 Cabin air filter
1. Remove the glove compartment.
2. Detach and remove the cabin air filter access door.
3. NOTE: The RH flap on the cabin air filter must be deflected downward to clear the glove
compartment damper when removing and installing the filter.
Remove the cabin air filter.
Cabin Air Filter 5055

Cabin Air Filter 5056


Manual
REMOVAL AND
INSTALLATION
Clutch and Clutch Field Coil
Special Tool(s)
Holding Fixture, Compressor Clutch Disc

and Hub
412-134

1 W712303 A/C clutch disc and hub bolt
2 19D786 A/C clutch disc and hub
3 19D648 A/C clutch disc and hub spacers
4 W712302 A/C compressor pulley snap ring
5 19D784 A/C compressor pulley
6 W712301 A/C clutch field coil snap ring
7 W712300 A/C clutch field coil electrical connector clip screw
8 19D798 A/C clutch field coil
Removal
1. Remove the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor
- 2.5L or Air Conditioning (A/C) Compressor - 3.0L, 3.5L in this section.
2. Remove the 3 screws and the A/C clutch shield (if equipped).
Clutch and Clutch Field Coil 5057

3. Remove the A/C clutch disc and hub bolt.
1. Hold the A/C clutch disc and hub with the Compressor Clutch Disc and Hub Holding Fixture.
2. Remove the A/C clutch disc and hub bolt.
4. Remove the A/C clutch disc and hub.
5. Remove the A/C compressor pulley snap ring.
6. Remove the A/C compressor pulley.
7. Remove the A/C clutch field coil electrical connector clip screw.
8. Remove the A/C clutch field coil snap ring.
9. Remove the A/C clutch field coil.
Installation
1. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for
damage.
• Inspect for physical damage, including cracked or melted components or discoloration due to
excessive heat.
• Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C
compressor pulley that is more than fingernail depth.
• Inspect for roughness in the A/C compressor pulley bearing.
2. Clean the A/C clutch field coil and pulley mounting surfaces.
3. Install the A/C clutch field coil.
4. Install the A/C clutch field coil snap ring.
5. Install the A/C clutch field coil electrical connector clip screw.

6. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head. It must be correctly aligned
during installation.
Install the A/C clutch pulley.
7. Install the A/C clutch pulley snap ring.
8. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening.
9. Install the A/C clutch disc and hub assembly.
10. Install the A/C clutch disc and hub bolt.

1. Hold the A/C clutch disc and hub with the Compressor Clutch Disc and Hub Holding Fixture.
2. Install the A/C clutch disc and hub bolt.
11. Install the A/C clutch shield and the 3 screws (if equipped).
12. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers.
13. Install the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor -
2.5L or Air Conditioning (A/C) Compressor - 3.0L, 3.5L in this section.



Manual
REMOVAL AND
INSTALLATION
Compressor Manifold and Tube Assembly - 2.5L
Material
Item Specification
Compressor Oil
YN-12-D

1 - Coolant reservoir hose retainer (part of 8276)
2 W503924 Washer reservoir filler neck bolt
3 W520413 Compressor manifold and tube suction fitting nut
4 W520413 Condenser inlet fitting nut
5 W701625 Compressor manifold bolt
6 19D734 Compressor manifold and tube assembly
100-02 .
3. Detach the coolant reservoir hose retainers from the compressor manifold and tube assembly.
4. Remove the washer reservoir filler neck bolt.

Compressor Manifold and Tube Assembly - 2.5L 5061

5. Remove the compressor manifold and tube suction fitting nut and disconnect the fitting.
8. Remove the compressor manifold bolt and detach the manifold from the A/C compressor.
9. Remove the compressor manifold and tube assembly.

• Add the correct amount of clean PAG oil to the refrigerant system. For additional
information, refer to the Refrigerant Oil Adding procedure in Section 412-00A .
412-00A .
Compressor Manifold and Tube Assembly - 2.5L 5062


Manual
REMOVAL AND
INSTALLATION
Compressor Manifold and Tube Assembly - 3.0L, 3.5L
Material
Item Specification
Compressor Oil
YN-12-D
NOTE: 3.0L shown, 3.5L similar.

1 W701625 Compressor manifold bolt
3 - Coolant reservoir hose retainer (2 required)
6 19D734 Compressor manifold and tube assembly
NOTICE: Do not stress or bend the aluminum lines on the compressor manifold and tube assembly to
facilitate removal. Bending or squeezing the lines together may damage the welds and lead to
premature failure of the line.
NOTICE: Use only the Air Conditioning (A/C) refrigerant compoil specified for this vehicle
All vehicles
Compressor Manifold and Tube Assembly - 3.0L, 3.5L 5063

100-02 .
4. Remove the compressor manifold bolt and detach the manifold from the A/C compressor.
5. Detach the 2 coolant reservoir hose retainers from the compressor manifold and tube assembly.

3.5L vehicles
9. NOTE: Be sure not to strike the A/C lines against any hard object such as the exhaust manifold when
removing the compressor manifold and tube assembly.
Remove the compressor manifold and tube assembly.
1. Rotate the compressor manifold and tube counterclockwise enough to allow it to be lifted
between the exhaust manifold shield and alternator.
2. Remove the compressor manifold and tube assembly.
3.0L vehicles
10. NOTE: Be sure not to strike the A/C lines against any hard object such as the exhaust manifold when
removing the compressor manifold and tube assembly.
Remove the compressor manifold and tube assembly.
All vehicles


• Add the correct amount of clean PAG oil to the refrigerant system. For additional
information, refer to the Refrigerant Oil Adding procedure in Section 412-00A .
412-00A .


Manual
REMOVAL AND
INSTALLATION
Compressor to Condenser Discharge Line - Hybrid
Material
Item Specification
Oil
YN-32

2 W701626 Lower rear A/C compressor bolt
3 W520413 A/C compressor discharge fitting nut
4 19D734 Compressor-to-condenser discharge line
5 19B596 Gasket seal (1 piece from kit required)
and contaminate the refrigerant system. Refer to the Refrigerant Oil Adding procedure in Section
412-00A .
100-02 .
3. Disconnect the condenser inlet fitting nut and disconnect the fitting.
Compressor to Condenser Discharge Line - Hybrid 5066

4. Remove the lower rear A/C compressor bolt.
5. Remove the A/C compressor discharge fitting nut and remove the compressor-to-condenser discharge
line.
Compressor Oil tthe hybrid vehicle refrigerant system will damage the electric Air
• Install a new O-ring seal and new gasket seals.

412-00A .
Compressor to Condenser Discharge Line - Hybrid 5067


Manual
REMOVAL AND
INSTALLATION
Condenser Core - 2.5L, 3.0L, Hybrid
Material
Item Specification
Compressor Oil
YN-32
Compressor Oil
YN-12-D

2 W500214 Radiator bracket bolt (2 required)
3 8A193 Radiator bracket (2 required)
4 W520413 Condenser fitting nut (2 required)
5 W711622 Condenser manifold pin-type retainer
6 19712 Condenser core
Condenser Core - 2.5L, 3.0L, Hybrid 5068

to the hybrid vehicle refrigerant system will damage the electric Air Conditioning ressor and
All vehicles
2.5L or 3.0L vehicles
2. Remove the Air Cleaner (ACL). For additional information, refer to Section 303-12A or Section
303-12B .
All vehicles
3. Remove the engine cooling fan. For additional information, refer to Section 303-03A or Section
303-03B .

3.0L vehicles
5. Remove the Thermostatic Expansion Valve (TXV) suction fitting nut and disconnect the fitting.
All vehicles
6. Remove the 2 condenser fitting nuts and disconnect the fittings.

7. Remove the 2 radiator bracket bolts and remove the 2 radiator brackets.
8. Remove the condenser manifold pin-type retainer.
9. Detach the 2 condenser core retaining clips and detach the condenser core from the radiator.
10. Remove the condenser core.
11. NOTICE: Motorcraft® Electric A/C Compressor Oil only must b used as a refrigerant system

• Add the correct amount of clean PAG oil (non-hybrid vehicles) or electric A/C compressor oil
(hybrid vehicles) to the refrigerant system. For additional information, refer to the Refrigerant
Oil Adding procedure in Section 412-00A .
412-00A .


Manual
REMOVAL AND
INSTALLATION
Condenser Core - 3.5L
Material
Item Specification
Compressor Oil
YN-12-D

1 W525884 Power steering hose clamp (2 required)
2 W520413 Condenser fitting nut (2 required)
3 19712 Condenser core
2. Remove adiator. For additional information, refer to Section 303-03A .
3. Release the 2 power steering cooler hose clamps and disconnect the power steering cooler hoses from
the condenser core.
4. Remove the 2 condenser fitting nuts and disconnect the fittings.

5. Remove the condenser core.
Condenser Core - 3.5L 5071


• Add the correct amount of clean PAG oil. For additional information, refer to the Refrigerant
Oil Adding procedure in Section 412-00A .
412-00A .
Condenser Core - 3.5L 5072


Manual
REMOVAL AND
INSTALLATION
Evaporator Core
Material
Item Specification
Compressor Oil
YN-32
Compressor Oil
YN-12-D

1 W712320 Evaporator core cover screw (11 required)
2 19W700 Dash panel seal
3 W712320 LH temperature blend door actuator screw (2 required)
4 19E616 LH temperature blend door actuator
5 W712320 RH temperature blend door actuator screw (2 required)
6 19E616 RH temperature blend door actuator
7 18B545 Temperature blend door (2 required)
8 19930 Heater core and evaporator core housing divider
9 19860 Evaporator core
412-00A .
Evaporator Core 5073

NOTE: If an evaporator core leak is suspected, the evaporator core must be leak tested before it is removed
from the vehicle.
All vehicles
1. Remove the heater core and evaporator core housing. For additional information, refer to Heater Core
And Evaporator Core Housing in this section.
2. Detach the wire harness from the heater core and evaporator core housing.
3. Remove the 11 evaporator core cover screws.
4. Separate the 2 halves of the heater core and evaporator core housing.
5. Remove the dash panel seal.
6. Remove the 2 LH temperature blend door actuator screws and detach the actuator.
Dual-zone Electronic Automatic Temperature Control (EATC) vehicles
7. Remove the 2 RH temperature blend door actuator screws and detach the actuator.
8. Remove the 2 temperature blend doors.
Electronic Manual Temperature Control (EMTC) vehicles
9. Remove the temperature blend door.
All vehicles
10. Remove the heater core and evaporator core housing divider from the heater core and evaporator core
housing.
11. Remove the evaporator core.
• Add the correct amount of clean PAG oil (non-hybrid) or electric A/C compressor oil (hybrid)
to the refrigerant system. For additional information, refer to Section 412-00A .



Manual
REMOVAL AND
INSTALLATION
Evaporator to Compressor Suction Line - Hybrid
Material
Item Specification
Oil
YN-32

1 W712963 Evaporator-to-compressor suction line bracket bolt
2 W520413 Evaporator outlet line fitting nut
3 W520413 A/C compressor suction fitting nut
4 19D734 Evaporator-to-compressor suction line
5 19B596 Gasket seal
412-00A .
2. Detach the block heater wire harness clip from the evaporator-to-compressor suction line (if
equipped).
3. Remove the evaporator-to-compressor suction line bracket bolt.

Evaporator to Compressor Suction Line - Hybrid 5076

4. Remove the evaporator outlet line fitting nut and disconnect the fitting.
5. Remove the A/C compressor suction fitting nut and disconnect the fitting.
6. Remove the evaporator-to-compressor suction line.
• Install a new O-ring seal and new gasket seals.

412-00A .
Evaporator to Compressor Suction Line - Hybrid 5077


Manual
REMOVAL AND
INSTALLATION
Heater Core

1 W712320 Heater core cover screw (8 required)
2 18B300 Heater core cover
3 19C593 Dash panel seal
4 18476 Heater core
NOTE: If a heater core leak is suspected, the heater core must be pressure leak tested before it is removed
from the vehicle. For additional information, refer to Section 412-00A .
1. Remove the heater core and evaporator core housing. For additional information, refer to Heater Core
And Evaporator Core Housing in this section.
2. Detach the wire harness from the heater core cover.
3. Remove the 8 heater core cover screws.
4. Remove the heater core cover.
5. Remove the dash panel seal from the heater core tubes.
6. Remove the heater core.
Heater Core 5078

Heater Core 5079


Manual
REMOVAL AND
INSTALLATION
Heater Core And Evaporator Core Housing
Material
Item Specification
Compressor Oil
YN-32
Compressor Oil
YN-12-D
ItemPart Number Description

1 W520413 Thermostatic Expansion Valve (TXV) fitting nut
2 8287 Heater hose clamp (2 required)
3 N621907 Heater core and evaporator core housing nut (6
required)
4 - Heater core and evaporator core housing
412-00A .
NOTICE: Use only the Air Condg (A/C) refrigerant compressor oil specified for this vehicle
3.5L vehicles
Heater Core And Evaporator Core Housing 5080

All vehicles
3. Drain the engine coolant. For additional information, refer to Section 303-03A .
5. Disconnect the A/C pressure transducer electrical connector and detach the wire harness from the
Thermostatic Expansion Valve (TXV) stud.
6. Remove the TXV fitting nut and disconnect the fitting.

7. Release the 2 heater hoses clamps and disconnect the hoses from the heater core.
8. Remove the 6 heater core and evaporator core housing nuts.

9. Remove the heater core and evaporator core housing.
To instl, reverse the removal procedure.

11. Fill the engine coolant level. For additional information, refer to Section 303-03A .
412-00A .



Manual
REMOVAL AND
INSTALLATION
Heating Ventilation Air Conditioning (HVAC) Module - Fusion, Milan
With Navigation System

1 W707628 HVAC module screw (2 required)
2 - HVAC module electrical connector (2
required) (part of 14401)
3 19980 HVAC module
Without Navigation System

5 19980 HVAC module
Heating Ventilation Air Conditioning (HVAC) Module - Fusion, Milan 5083

Vehicles equipped with navigation system
1. Remove the Front Display Interface Module (FDIM). For additional information, refer to Section
415-00 .
2. Remove the 2 HVAC module screws.
3. Disconnect the 2 HVAC module electrical connectors and remove the HVAC module.
Vehicles without navigation system
4. Remove the center instrument panel finish panel. For additional information, refer to Section 501-12 .
5. Remove the 4 HVAC module screws and remove the HVAC module.
All vehicles
Without Navigation System 5084


Manual
REMOVAL AND
INSTALLATION
Heating Ventilation Air Conditioning (HVAC) Module - MKZ

2 - HVAC module electrical connector (part of 14401)
3 19980 HVAC module
1. Remove the Front Display Interface Module (FDIM). For additional information, refer to Section
415-00 .
2. Remove the 2 HVAC module screws.
3. Disconnect the 2 HVAC module electrical connectors.
4. Remove the HVAC module.
Heating Ventilation Air Conditioning (HVAC) Module - MKZ 5085

Heating Ventilation Air Conditioning (HVAC) Module - MKZ 5086


Manual
REMOVAL AND
INSTALLATION
In-Vehicle Temperature and Humidity Sensor - Hybrid
Part
1 - In-vehicle temperature and humidity sensor electrical
connector (part of 14401)
2 19C734 In-vehicle temperature and humidity sensor
1. Remove the instrument cluster finish panel. For additional information, refer to Section 501-12 .
2. Disconnect the in-vehicle temperature and humidity sensor electrical connector.
3. Remove the in-vehicle temperature and humidity sensor.



Manual
REMOVAL AND
INSTALLATION
In-Vehicle Temperature Sensor - Fusion, Milan
Fusion, Milan
Part
1 - In-vehicle temperature sensor aspirator hose connection
(part of 19C734)
2 - In-vehicle temperature sensor aspirator hose pin-type
retainer (part of 19C734)
3 - In-vehicle temperature sensor electrical connector (part
of 14401)
4 19C734 In-vehicle temperature sensor
2. Disconnect the in-vehicle temperature sensor aspirator hose connection at the heater core and
evaporator core housing.
3. Detach the in-vehicle temperature sensor aspirator hose pin-type retainer.
4. Disconnect the in-vehicle temperature sensor electrical connector.
5. Remove the itemperature sensor and aspirator hose assembly.
In-Vehicle Temperature Sensor - Fusion, Milan 5089

Fusion, Milan 5090


Manual
REMOVAL AND
INSTALLATION
In-Vehicle Temperature Sensor - MKZ
MKZ
Part
(part of 19C734)
2 - In-vehicle temperature sensor aspirator hose pin-type
retainer (part of 19C734)
3 54044A90 RH instrument panel finish moulding
4 54046A76 In-vehicle temperature sensor grille
5 - In-vehicle temperature sensor electrical connector (part
of 14401)
6 19C734 In-vehicle temperature sensor
7 W707607 RH instrument panel finish moulding screw (4 required)
2. Disconnect the in-vehicle temperature sensor aspirator hose connection at the heate evaporator core
housing.
3. Detach the in-vehicle temperature sensor aspirator hose pin-type retainer.
4. Lower the glove compartment.
5. Remove the 4 RH instrument panel finish moulding screws.
6. Remove the RH instrument panel finish moulding.
7. Detach the in-vehicle temperature sensor grille from the instrument panel.
In-Vehicle Temperature Sensor - MKZ 5091

8. Detach the in-vehicle temperature sensor grille from the in-vehicle temperature sensor.
9. Disconnect the in-vehicle temperature sensor electrical connector.
10. Remove the in-vehicle temperature sensor and aspirator hose assembly.
MKZ 5092

Manual
REMOVAL AND
INSTALLATION
Mode Door Actuator - Air Inlet Door
Part
1 04480 Instrument panel side finish panel
2 5406010 Glove compartment storage bin
3 - Air inlet mode door actuator electrical connector (part
of 19D887)
4 W712320 Air inlet mode door actuator screw (2 required)
5 19E616 Air inlet mode door actuator
2. Remove the RH instrument panel end panel.
3. Remove the glove compartment storage bin.
4. Disconnect the air inlet mode door actuator electrical connector.
5. Remove the 2 air inlet mode door actuator screws.
6. Remove the air inlet mode door actuator.
Mode Door Actuator - Air Inlet Door 5093

Mode Door Actuator - Air Inlet Door 5094


Manual
REMOVAL AND
INSTALLATION
Mode Door Actuator - Defrost/Panel/Floor Door
Part
1 - LH temperature blend door actuator electrical connector
(part of 19D887)
(part of 19C734)
5 - DEFROST/PANEL/FLOOR mode door actuator
electrical connector (part of 19D887)
6 W712320 DEFROST/PANEL/FLOOR mode door actuator and
cam assembly screw
7 19C772 DEFROST/PANEL/FLOOR mode door actuator and
cam assembly
2. Disconnect the LH temperature blend dor electrical connector.
3. Remove the 2 LH temperature blend door actuator screws.
4. Remove the LH temperature blend door actuator.
5. Disconnect the in-vehicle temperature sensor aspirator hose connection.
6. Disconnect the DEFROST/PANEL/FLOOR mode door actuator electrical connector.
7. Remove the 3 DEFROST/PANEL/FLOOR mode door actuator and cam assembly screws.
8. Remove the DEFROST/PANEL/FLOOR mode door actuator and cam assembly.
Mode Door Actuator - Defrost/Panel/Floor Door 5095

10. NOTE: The purpose of the module actuator position calibration is to allow the HVAC module to
reinitialize and calibrate the actuator stop points. To carry out calibration, carry out the following
steps.
Remove the Smart Junction Box (SJB) fuse 15 for at least one minute.
11. NOTE: When the ignition switch is switched to the ON position, the HVAC module will initialize
and calibrate the actuators. Calibration of the actuators will take approximately 30 seconds.
Reinstall SJB fuse 15. Turn the ignition switch to the ON position and wait 30 seconds before
verifying correct DEFROST/PANEL/FLOOR operation.
Mode Door Actuator - Defrost/Panel/Floor Door 5096


Manual
REMOVAL AND
INSTALLATION
Receiver Drier Cartridge
Material
Item Specification
Compressor Oil
YN-32
Compressor Oil
YN-12-D
412-00A .
NOTICE: Care must be taken to minimize exposure of the receiver/drier cartridge to outside air. If
multiple Air Conditioning (A/C) system components are being removed and installed, the receiver/drier
cartridge should be installed last. The new receiver/drier cartridge should not be removed from its
packaging until it is ready to be installed. Evacuation of the A/C system must be started as soon as the
receiver/drier cartridge is installed. Excessive exposure of the receiver/drier cartridge to outside air will
result in moisture contamination of the receiver/drier cartridge desiccant.
when there is physical evidence of contamination from a failed A/C compressor or damage to the rec/drier
cartridge. Damage to the receiver/drier cartridge includes physical damage or moisture contamination.
Moisture contamination results only from a complete loss of refrigerant, and equalization of the refrigerant
system pressure with atmospheric pressure for a period longer than one hour. If even a slight amount of
positive refrigerant pressure is present in the refrigerant system before repairs are carried out, the
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer Section
100-02 .
3. Remove the lower radiator air deflector.
4. Unscrew and remove the plastic receiver/drier cap.
Receiver Drier Cartridge 5097

5. NOTE: If the receiver/drier plug is difficult to remove, open a refrigerant system fitting to relieve any
vacuum created during refrigerant recovery, and attempt to remove the plug again.
Remove the receiver/drier plug.
1. Push the receiver/drier plug upwards and remove the snap ring.
2. Install the bolt included with the A/C desiccant cartridge service kit in the center of the
receiver drier plug and remove the plug.
6. Using a suitable tool, grasp the receiver/drier cartridge grab handle and remove the receiver/drier
cartridge.
To install, reverse the removal procedu.
• Lubricate the receiver/drier plug O-ring seals using residual refrigerant oil from inside the
receiver/drier.
412-00A .



Manual
REMOVAL AND
INSTALLATION
Register - Center, Fusion/Milan

1 19893 RH center instrument panel register
2 19893 LH center instrument panel register
1. Remove the instrument panel upper storage compartment. For additional information, refer to Section
501-12 .
2. Release the clips on each register and remove the 2 center instrument panel registers.
Register - Center, Fusion/Milan 5100

Register - Center, Fusion/Milan 5101


Manual
REMOVAL AND
INSTALLATION
Register - Center, MKZ

1 19893 RH center register
2 19893 LH center register
1. Remove the center instrument panel finish panel. For additional information, refer to Section 501-12 .
2. Detach the RH and LH center register clips and remove the RH and LH center registers.
Register - Center, MKZ 5102


Manual
REMOVAL AND
INSTALLATION
Register - Driver and Passenger Side, Fusion/Milan

1 04480 RH/ 04481 LH Instrument panel side finish panel
2 19893 Register
NOTE: Passenger side register shown, driver side similar.
1. Remove the instrument panel end panel.
2. Working through the instrument panel end panel opening, release the 2 lower register clips and
remove the driver or passenger side instrument panel register.
Register - Driver and Passenger Side, Fusion/Milan 5103


Manual
REMOVAL AND
INSTALLATION
Register - LH, MKZ

1 - LH instrument panel register screw (2 required)
2 19893 LH instrument panel register
2. Remove the 2 LH instrument panel register screws.
3. Remove the LH register.
Register - LH, MKZ 5104

Register - LH, MKZ 5105


Manual
REMOVAL AND
INSTALLATION
Register - RH, MKZ

1 54044A90 RH instrument panel finish moulding
2 - RH register screw
3 19893 RH register
4 W707607 RH instrument panel finish moulding screw (4
required)
3. Remove the 4 RH instrument panel finish moulding screws.
4. Remove the RH instrument panel finish moulding.
5. Remove the RH register screw.
6. Remove the RH register.
Register - RH, MKZ 5106

Register - RH, MKZ 5107


Manual
REMOVAL AND
INSTALLATION
Temperature Blend Door Actuator - LH
Part
1 - LH temperature blend door actuator electrical connector
(part of 19D887)
NOTE: The LH temperature blend door actuator can be accessed from below the LH side of the instrument
panel to the right of the accelerator pedal.
1. Disconnect the LH temperature blend door actuator.
2. Remove the 2 LH temperature blend door actuator screws.
3. Remove the LH temperature blend door actuator.
5. NOTE: The purpose of the module actuator position calibration is to allow the HVAC module to
steps.
and calibrate the actuators. Calibration of the actuators will take approximately 30 seconds. SJB fuse
15. Turn the ignition switch to the ON position and wait 30 seconds before verifying correct
DEFROST/PANEL/FLOOR operation.
Temperature Blend Door Actuator - LH 5108

Temperature Blend Door Actuator - LH 5109


Manual
REMOVAL AND
INSTALLATION
Temperature Blend Door Actuator - RH, Dual-Zone EATC
Part
1 W712320 RH temperature blend door actuator screw (2 required)
2 - RH temperature blend door actuator electrical connector
(part of 19D887)
3 19E616 RH temperature blend door actuator
1. Remove the passenger air bag module. For additional information, refer to Section 501-20B .
2. Disconnect the RH temperature blend door actuator electrical connector.
3. Remove the 2 RH temperature blend door actuator bracket screws.
4. Detach the wire harness from the RH temperature blend door actuator bracket.
5. Remove the RH temperature blend door actuator.
7. NOTE: The purpose of the module actuator position calibris to allow the HVAC module to
steps.
and calibrate the actuators. Calibration of the actuators will take approximately 30 seconds.
Reinstall SJB fuse 15. Turn the ignition switch to the ON position and wait 30 seconds before
verifying correct DEFROST/PANEL/FLOOR operation.
Temperature Blend Door Actuator - RH, Dual-Zone EATC 5110

Temperature Blend Door Actuator - RH, Dual-Zone EATC 5111


Manual
REMOVAL AND
INSTALLATION
Thermostatic Expansion Valve
Material
Item Specification
Compressor Oil
YN-32
Compressor Oil
YN-12-D

1 - A/C pressure transducer electrical connector
(part of 14290)
2 W520413 Thermostatic Expansion Valve (TXV) fitting
nut
3 W712321 TXV bolt (2 required)
4 19849 TXV
412-00A .
Thermostatic Expansion Valve (TXV) stud.
Thermostatic Expansion Valve 5112

4. Remove the 2 TXV bolts.
5. Remove the TXV .

6. NOTICE: Motorcraft® Electric A/C Compressor Oil only must be used as a refrierant system

412-00A .
Thermostatic Expansion Valve 5113


Manual
REMOVAL AND
INSTALLATION
Thermostatic Expansion Valve Manifold and Tube Assembly
Material
Item Specification
Compressor Oil
YN-32
Compressor Oil
YN-12-D
Part
1 W520413 Condenser-to-evaporator line fitting nut
3 W707399 Thermostatic Expansion Valve (TXV) manifold and
tube bracket bolt
4 14290 A/C pressure transducer electrical connector
5 W520413 TXV fitting nut
6 19835 TXV manifold and tube assembly
to the hybrid vehicle refrigerant system will damage the electric Air Conditioning) compressor and
Thermostatic Expansion Valve Manifold and Tube Assembly 5114

All vehicles
3.5L vehicles
Non-hybrid vehicles
3. Detach the wire harness pin-type retainer at the front of the RH shock tower and detach the 2 wire
harness clips from the Thermostatic Expansion Valve (TXV) manifold and tube assembly.
All vehicles
4. Remove the condenser-to-evaporator line fitting nut and disconnect the fitting.
6. Remove the TXV manifold and tube bracket bolt.

TXV manifold and tube assembly.

9. Remove the TXV manifold and tube assembly.
10. NOTICE: Motorcraft® Elecric A/C Compressor Oil only must be used as a refrigerant system
• Install new O-ring seals and new gasket seals.

412-00A .

SECTION 413-00: Instrument Cluster and Panel 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid
Illumination Workshop Manual
Instrument Cluster and Panel Illumination
NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM).
Illumination is used to provide backlighting to the dimmable and non-dimmable switches and control
components.
If the exterior lamps are activated during daytime sunload conditions by the autolamp system, the Instrument
Panel Cluster (IPC) message center (non-Hybrid) or the Liquid Crystal Display (LCD) (Hybrid), Audio
Control Module (ACM), Front Controls Interface Module (FCIM), Front Display Interface Module (FDIM),
the HVAC module and switch illumination remain at full intensity and do not dim from the instrument panel
dimmer switch during this condition. If the vehicle travels under a bridge or a tunnel, the low level of ambient
light causes the illumination level of the IPC message center (non-Hybrid) or the LCD (Hybrid), the ACM ,
the FCIM , the FDIM , the HVAC module and switches to change to the level set by the instrument panel
dimmer switch. The IPC message center (non-Hybrid) or the LCD (Hybrid), the ACM , the FCIM , the FDIM
, the HVAC module and switch illumination change back to full intensity when the intense ambient light is
restored.
Dimmable Backlighting
The dimmable switches and components are illuminated when the parking lamps are ON. The digital dimmer
switch is a double detent rocker switch used to control all dimmable interior illuminated components, and to
control the courtesy lamps. The first up detent increases dimmable backlighting intensity. The first down
detent decreases dimmable backlighting intensity.
The second up detent turns on the courtesy lamps. The second down detent turns the courtesy lamps off unless
other features are still requesting the courtesy lamps on.
The dimmable switches and components consist of:
• Ambient lighting/traction control switch (if equipped) (Fusion)

• Ambient lighting select switch (if equipped) (MKZ)
• Ambient lighting dimmer switch (if equipped) (MKZ)
• Audio Control Module (ACM)
• Luggage compartment lid release switch
• Door lock control switches (MKZ)
• Front Controls Interface Module (FCIM)
• Front Display Interface Module (FDIM)
• Hazard flasher lamp switch (Fusion)
• Headlamp switch
• HVAC module
• Instrument Panel Cluster (IPC)
• Instrument panel dimmer switch
• Memory set switch (MKZ)
• Message center switch (Fusion)
• Speed control switches
• Steering wheel audio control switches
• Floor shifter
• Window control switches (MKZ)
Instrument Cluster and Panel Illumination 5117

Non-Dimmable Backlighting
The non-dimmable lighting switches and components are illuminated when the accessory delay relay is
energized. The non-dimmable switches and components are illuminated at full lamp intensity. The
non-dimmable lighting switches and components consist of:
• Cigar lighter (MKZ)

• Door lock control switches (Fusion)
• Roof opening panel switch (if equipped)
• Window control switches (Fusion)

SECTION 413-00: Instrument Cluster and Panel 2012 Fusion, MKZ, Fusion Hybrid, MKZ
Illumination Hybrid Workshop Manual
Instrument Cluster and Panel Illumination
Special Tool(s)


Flex Probe Kit
Dimmable Backlighting
When the parking lamps are on, the SJB sends a pulse-width modulated voltage to the hardwired dimmable
components and switches based on input received from the instrument panel dimmer switch.
The SJB also sends a message over the network to the Audio Control Module (ACM), Front Controls
Interface Module (FCIM), Front Display Interface Module (FDIM), the HVAC module, and the Instrument
Panel Cluster (IPC) to indicate the backlighting intensity level. If the receiving module receives invalid
backlighting data from the SJB for 5 seconds or less, the receiving module defaults the backlighting to the last
setting.
If the receiving module does not receive the backlighting status message from the SJB or if the data received
is deemed invalid for more than 5 seconds, the receiving module sets a DTC in continuous memory and
defaults the backlighting to full nighttime intensity.
Fixed Backlighting
For Fusion, when the accessory delay relay is energized, switched voltage is supplied to the window control
and door lock control switches.
For MKZ, when the accessory delay relay is energized, switched voltage is supplied to the roof opening panel
switch and the cigar lighter.
Field-Effect Transistor (FET) Protection
Field-Effect Transistor (FET) is a type of transistor that when used with module software can be used to
monitor and control current flow on module outputs. The FET protection strategy is used to prevent module
damage in the event of excessive current flow.

The SJB utilizes a FET protective circuit strategy for many of its outputs (for example, a headlamp output
circuit). Output loads (current level) are monitored for excessive current (typically short circuits) and are shut
down (turns off the voltage or ground provided by the module) when a fault event is detected. A continuous
DTC is stored at the fault event and a cumulative counter is started.
When the demand for the output is no longer present, the module resets the FET circuit protection to allow the
circuit to function. The next time the driver requests a circuit to activate that has been shut down by a previous
short ( FET protection) and the circuit remains shorted, the FET protection shuts off the circuit again and the
cumulative counter advances.
When the excessive circuit load occurs often enough, the module shuts down the output until a repair
procedure is carried out. Each FET protected circuit has 3 predefined levels of short circuit tolerance based on
the harmful effect of each circuit fault on the FET and the ability of the FET to withstand it. A module
lifetime level of fault events is established based upon the durability of the FET . If the total tolerance level is
determined to be 600 fault events, the 3 predefined levels would be 200, 400 and 600 fault events.
When each tolerance level is reached, the continuous DTC that was stored on the first failure cannot be
cleared by a command to clear the continuous DTCs. The module does not allow this code to be cleared or the
circuit restored to normal operation until a successful self-test proves that the fault has been repaired. After the
self-test has successfully completed (no on-demand DTCs present), DTC B106E and the associated
continuous DTC (the DTC related to the shorted circuit) automatically clears and the circuit function returns.
When the first or second level is reached, the continuous DTC (associated with the short circuit) sets along
with DTC B106E. These DTCs can be cleared using the module on-demand self-test, then the Clear DTC
operation on the scan tool (if the on-demand test shows the fault corrected). The module never resets the fault
event counter to zero and continues to advance the fault event counter as short circuit fault events occur.
If the number of short circuit fault events reach the third level, then DTCs B106F and B1342 set along with
the associated continuous DTC. This DTC cannot be cleared and the module must be replaced.
The SJB FET protected output circuit for the instrument panel illumination system is the backlighting output
circuit.
2. Visually inspect for obvious signs of electrical damage.
Electrical
fuse(s):
♦ 10 (15A) (dimmable
illumination)
♦ 41 (15A)
(non-dimmable
illumination)
• Wiring, terminals or
connectors
• Illuminated components

• SJB
• Check the VCM connection to the vehicle.

• Check the scan tool connection to the VCM .
• Refer to Section 418-00 , No Power To The Scan Tool, to diagnose no power to the scan tool.

• Verify the ignition key is in the ON position.
• Verify the scan tool operation with a known good vehicle.
• Refer to Section 418-00 to diagnose no response from the PCM.

418-00 .
9. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to the
Diagnostic Trouble Code (DTC) Chart in Section 419-10 .
DTC Charts

B106E Solid State Driver The module has temporarily disabled an output because an excessive current
Disabled Due to draw exists (such as a short to ground). The SJB cannot enable the output until
Short Circuit the cause of the short is corrected. ADDRESS all other DTCs first. After the
cause of the concern is corrected, CLEAR the DTCs. REPEAT the self-test.
B106F Module Disabled The module has permanently disabled an output because an excessive current
Due to External draw fault (such as a short to ground) has exceeded the limits that the SJB can
Fault withstand. The cause of the excessive current draw MUST be corrected before
a new SJB is installed. ADDRESS all other DTCs first. After the cause of the
concern is corrected, INSTALL a new SJB . TEST the system for normal
operation.
B213A GO to Pinpoint Test A .

Digital Dimmer
Switch Input
Circuit Failure
B29B7 White Lighting If the backlighting components are inoperative, GO to Pinpoint Test B .
Output Circuit
Open If the backlighting components are always on, GO to Pinpoint Test C .
B29B8 White Lighting GO to Pinpoint Test C .
Output Circuit
Short to Ground
B2A32 LED Backlighting If the backlighting components are inoperative, GO to Pinpoint Test B .
Output Circuit
Open If the hardwired backlighting components are always on, GO to Pinpoint Test
C.
B2A33 LED Backlighting GO to Pinpoint Test B .
Output Circuit
Short to Ground
All - REFER to the Diagnostic Trouble Code (DTC) Chart in Section 419-10 .
other
DTCs
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: All Dimmable Illumination Does Not Dim/Increase Brightness
Refer to Wiring Diagrams Cell 71 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Cluster and Panel
Illumination for schematic and connector information.
Normal Operation
The Smart Junction Box (SJB) sends voltage signals to the instrument panel dimmer switch to monitor a
request to turn up the dimmable lighting, turn down the dimmable lighting and to turn the courtesy lamps on
or off. When the instrument panel dimmer switch is placed in the first detent up or down, the corresponding
input signal is routed to ground indicating a request to turn the dimmable lighting up or down. When the
instrument panel dimmer switch is pressed to the second detent, the dome lamp request input circuit is routed
to ground in addition to the dimmer up or dimmer down input circuit. The SJB needs a dimmer up/down input
circuit and the dome lamp request input circuit to turn the courtesy lamps on or off from the instrument panel
dimmer switch.
When the parking lamps or headlamps are ON, the Smart Junction Box (SJB) monitors the input from the
instrument panel dimmer switch to increase or decrease the dimmable lighting intensity.
If the dim up/dim down or the dome lamp request input circuit is shorted to ground for longer than 17
seconds, the SJB defaults the backlighting to full nighttime brightness.

• DTC B213A (Digital Dimmer Switch Input Circuit Failure) - a continuous and on-demand DTC that
sets when the SJB detects a short to ground from the dimmer up, dimmer down or dome lamp on/off
request input circuit.
• Wiring, terminals, or connectors

• SJB
PINPOINT TEST A: ALL DIMMABLE ILLUMINATION DOES NOT DIM/INCREASE BRIGHTNESS
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.

A1 CHECK FOR RECORDED DTCs FROM THE SJB
SELF-TEST
s
• Check the recorded DTCs from the SJB on-demand
self-test. No
• Is DTC B213A present? GO to A4 .
A2 REPEAT THE SJB SELF-TEST WITH THE
INSTRUMENT PANEL DIMMER SWITCH
DISCONNECTED
Yes
• Disconnect: Instrument Panel Dimmer Switch C2065. GO to A3 .
• Ignition ON.
• Enter the following diagnostic mode on the scan tool: SJB No
Self-Test. INSTALL a new instrument panel
• Clear the DTCs and repeat the SJB on-demand self-test. dimmer switch. REFER to
• Is on-demand DTC B213A still present? Instrument Panel Dimmer Switch in
this section. TEST the system for
normal operation.
A3 CHECK THE INSTRUMENT PANEL DIMMER
SWITCH INPUT CIRCUITS FOR A SHORT TO GROUND
Yes
• Disconnect: SJB C2280b.
• Measure the resistance between the instrument panel No
dimmer switch , harness side and ground as follows: REPAIR the circuit in question for a
Connector-Pin Circuit
C2065-2 CLN28 (GN/BU)
C2065-3 CLN27 (WH/BN)
C2065-7 CLN12 (YE)

5123

SWITCH
Yes
• Disconnect: Instrument Panel Dimmer Switch C2065. GO to A5 .
• Carry out the instrument panel dimmer switch component
test. No
INSTALL a new instrument panel
Refer to Wiring Diagrams Cell 149 ( Fusion/MKZ , Fusion dimmer switch. REFER to
Hybrid/MKZ Hybrid ) for component testing. Instrument Panel Dimmer Switch in
• Is the instrument panel dimmer switch OK? this section. TEST the system for
normal operation.
SWITCH DIM UP AND DIM DOWN INPUT CIRCUITS FOR
VOLTAGE
Yes
• Ignition ON. GO to A7 .
• Measure the voltage between the instrument panel dimmer
switch C2065-7, circuit CLN12 (YE), harness side and No
ground; and between the instrument panel dimmer switch GO to A6 .
C2065-3, circuit CLN27 (WH/BN), harness side and
ground.
• Are the voltages greater than 10 volts?

SWITCH DIM UP AND DIM DOWN CIRCUITS FOR AN
OPEN
Yes
• Measure the resistance between the instrument panel No
dimmer switch C2065-7, circuit CLN12 (YE), harness side REPAIR the circuit in question for
and the SJB C2280b-28, circuit CLN12 (YE), harness side. an open. TEST the system for
normal operation.

5124
• Measure the resistance between the instrument panel

dimmer switch C2065-3, circuit CLN27 (WH/BN), harness
side and the SJB C2280b-36, circuit CLN27 (WH/BN),
harness side.

SWITCH INPUT AND RETURN CIRCUITS FOR A SHORT
TO VOLTAGE
Yes
• Ignition OFF. REPAIR the circuit in question for a
• Disconnect: SJB C2280b. short to voltage. TEST the system
• Ignition ON. for normal operation.
• Measure the voltage between the instrument panel dimmer
switch , harness side and ground as follows: No
GO to A8 .
C2065-2 CLN28 (GN/BU)
C2065-3 CLN27 (WH/BN)
C2065-4 RLN29 (WH/OG)
C2065-7 CLN12 (YE)

5125

SWITCH RETURN CIRCUIT FOR AN OPEN
Yes
• Measure the resistance between the instrument panel
dimmer switch C2065-4, circuit RLN29 (WH/OG), harness No
side and the SJB C2280b-33, circuit RLN29 (WH/OG), REPAIR circuit CLN27 (WH/BN)
harness side. for an open. TEST the system for
normal operation.

Yes
• Disconnect all the SJB connectors. INSTALL a new SJB . REFER to
• Check for: Section 419-10 . TEST the system
♦ corrosion for normal operation.
♦ damaged pins
♦ pushed-out pins No
• Connect all the SJB connectors and make sure they seat The system is operating correctly at
correctly. this time. The concern may have
• Is the concern still present? connector.
Pinpoint Test B: All Dimmable Switch Illumination Is Inoperative
Normal Operation
When the parking lamps are on, the Smart Junction Box (SJB) sends a Pulse Width Modulated (PWM)
voltage to the hardwired dimmable illumination sources based on the input received from the instrument panel
dimmer switch.

A continuous DTC that sets when the SJB has temporarily shut down the output
• B106E - Solid driver. The module has temporarily disabled the backlighting output because an
State Driver excessive current draw exists (such as a short to ground). The SJB cannot enable the
Disabled Due backlighting output until the cause of the short is corrected, the DTCs have been
to Short cleared and a successful self-test is run.
Circuit

• B106F - A continuous DTC that seten the SJB has permanently shut down the output driver.
Module The module has permanently disabled the backlighting output because an excessive
Disabled Due current draw fault (such as a short to ground) has exceeded the limits that the SJB can
to External withstand. The cause of the excessive current draw MUST be corrected before a new
Fault SJB is installed.
An on-demand DTC that sets when the SJB detects an open from the backlighting
• B2A32 - LED output circuit.
Backlighting
Output Circuit
Open
A continuous and on-demand DTC that sets when the SJB detects a short to ground
• B2A33 - LED from the backlighting output circuit. The DTC also sets when fuse 10 (15A) has
Backlighting failed or is removed.
Output Circuit
Short To
Ground
An on-demand DTC that sets when the SJB detects an open from the white lighting
• B29B7 - (backlighting) circuit.
White
Lighting
Output Circuit
Open
• B29B8 - from the white lighting (backlighting) output circuit. This DTC also sets when fuse
White 10 (15A) has failed or is removed.
Lighting
Output Circuit
Short to
Ground
• Fuse
• SJB
PINPOINT TEST B: ALL DIMMABLE SWITCH ILLUMINATION IS INOPERATIVE

B1 CHECK FOR RECORDED SJB DTCs FROM THE
SELF-TEST
Yes
• Use the recorded results from the SJB self-test. VERIFY the SJB fuse 10 (15A) is OK.
• Is DTC B2A33 or DTC B29B8 present? IfK, GO to B2 .
If not OK, REFER to the Wiring

Diagrams Manual to identify the
PINPOINT TEST B: ALL DIMMABLE SWITCH ILLUMINATION IS INOPERATIVE 5127


After the repair:
If no DTCs are present, TEST the

If DTC B106E is present, CLEAR the

DTCs and REPEAT the self-test
(required to enable the backlighting
output driver if DTC B106E is
present) . TEST the system for normal
operation.
If DTC B106F is present, INSTALL a

new SJB . REFER to Section 419-10 .
No
GO to B2 .
B2 BYPASS THE SJB
Yes
NOTE: If the jumper wire fails, refer to the Wiring REMOVE the jumper wire. GO to B3 .
Diagrams Manual to identify the possible causes of the
circuit short. After the repair: No
REMOVE the jumper wire. REPAIR
If no DTCs are present, test the system for normal circuit VLN04 (VT/GY) (Fusion) or
operation. circuit VLN37 (BU/WH) (MKZ) for
If DTC B106E is present, Clear the DTCs and repeat the the self-test.
self-test (required to enable the backlighting output
driver if DTC B106E is present). TEST the system for
normal operation.
If DTC B106F is present, install a new SJB . Refer to

Section 419-10 . TEST the system for normal operation.
• Ignition OFF.
• For Fusion, connect a fused jumper wire between the
SJB C2280b-39, circuit VLN04 (VT/GY), harness side
and battery positive.
• For MKZ, connect a fused jumper wire between the SJB

C2280b-52, circuit VLN37 (BU/WH), harness side and
battery positive.
PINPOINT TEST B: ALL DIMMABLE SWITCH ILLUMINATION IS INOPERATIVE 5128

• Do the backlighting components illuminate?

Yes
• Check for: Section 419-10 . TEST the system for
♦ corrosion normal operation.
♦ damaged pins
correctly. this time. The concern may have been
• Is the concern still present? REPEAT the self-test.
Pinpoint Test C: All Dimmable Switch Illumination Is Always On
Normal Operation
When the parking lamps are on, the Smart Junction Box (SJB) sends a Pulse Width Modulated (PWM)
voltage to the hardwired dimmable illumination sources based on the input received from the instrument panel
dimmer switch.
• DTC B2A32 (LED Backlighting Output Circuit Open) - an on-demand DTC that sets when the SJB
detects a short to voltage from the backlighting output circuit.
• DTC B29B7 (White Lighting Output Circuit Open) - an on-demand DTC that sets when the SJB
detects a short to voltage from the white lighting (backlighting) output circuit.

• SJB
PINPOINT TEST C: ALL DIMMABLE SWITCH ILLUMINATION IS ALWAYS ON

C1 CHECK THE EXTERIOR LIGHTING

• Ignition ON. Yes

• Observe the exterior lighting components. REFER to Section 417-01 .
• Are any exterior lighting components
illuminated? No
GO to C2 .
C2 CHECK THE SJB BACKLIGHTING
VOLTAGE
Yes
• Ignition OFF. REPAIR circuit VLN04 (VT/GY) (Fusion) or
• Disconnect: SJB C2280b. circuit VLN37 (BU/WH) (MKZ) for a short to
• Ignition ON. voltage. CLEAR the DTCs. REPEAT the
• Do the dimmable backlighted components self-test.
continue to illuminate?
No
GO to C3 .
Yes
• Disconnect all the SJB connectors. INSTALL a new SJB . REFER to Section 419-10
• Check for: . TEST the system for normal operation.
♦ corrosion
♦ damaged pins No
♦ pushed-out pins The system is operating correctly at this time. The
• Connect all the SJB connectors and make concern may have been caused by a loose or
sure they seat correctly. corroded connector.
still present.
Pinpoint Test D: The Steering Wheel Control Illumination Is Inoperative
Normal Operation
The Smart Junction Box (SJB) sends a Pulse Width Modulated (PWM) voltage to the steering wheel controls
through the clockspring. The voltage passes through the clockspring to the steering wheel control switches.

• Steering wheel control switch(es)
• Steering wheel harness
• Clockspring
PINPOINT TEST D: THE STEERING WHEEL CONTROL ILLUMINATION IS INOPERATIVE
PINPOINT TEST C: ALL DIMMABLE SWITCH ILLUMINATION IS ALWAYS ON 5130


D1 CHECK THE OTHER DIMMABLE LIGHTING
SWITCHES
Yes
• Ignition OFF. GO to Pinpoint Test B .
• Place the headlamp switch in the PARKING LAMPS ON
position. No
• Increase the backlighting brightness to the highest setting. GO to D2 .
• Are all the dimmable switches inoperative?
D2 CHECK FOR VOLTAGE TO THE CLOCKSPRING
Yes
• Place the headlamp switch in the OFF position. GO to D3 .
• Depower the Supplemental Restraint System (SRS). Refer to
Section 501-20B . No
• Disconnect: Clockspring C218a. REPAIR circuit VLN04
• Connect: Negative Battery Cable. (VT/GY) (Fusion) or circuit
• Place the headlamp switch in the PARKING LAMPS ON VLN37 (BU/WH) (MKZ).
position. REPOWER the SRS . REFER to
• Rotate the instrument panel dimmer switch to the full Section 501-20B . TEST the
illumination position. system for normal operation.
• Measure the voltage between the clockspring C218a-16,
circuit VLN04 (VT/GY) (Fusion) or circuit VLN37 (BU/WH)
(MKZ), harness side and ground.

D3 CHECK FOR VOLTAGE TO THE CLOCKSPRING USING
THE CONNECTOR GROUND
Yes
• Measure the voltage between the clockspring C218a-16, GO to D4 .
circuit VLN04 (VT/GY) (Fusion) or circuit VLN37 (BU/WH)
(MKZ), harness side and the clockspring C218a-7, circuit No
GD116 (BK/VT), harness side. REPAIR circuit GD116
(BK/VT) for an open.
REPOWER the SRS . REFER to
Section 501-20B . TEST the

D4 CHECK THE CLOCKSPRING FOR AN OPEN
PINPOINT TEST D: THE STEERING WHEEL CONTROL ILLUMINATION IS INOPERATIVE 5131

• Remove the driver air bag module. Refer to Section 501-20B . Yes
• Disconnect: Upper Clockspring C218b. GO to D5 .
• Measure the resistance between the clockspring C218a pin 16,
component side and the upper clockspring C218b pin 7, No
component side. INSTALL a new clockspring.
REFER to Section 501-20B .
operation.
• Measure the resistance between the clockspring C218a pin 7,

component side and the upper clockspring C218b pin 2,
component side.

D5 CHECK THE STEERING WHEEL HARNESS VOLTAGE
CIRCUIT FOR AN OPEN
Yes
• Disconnect: Steering Wheel Switches C2997 and C2998. GO to D6 .
• Measure the resistance between the upper clockspring
C218b-7, circuit VLN04 (VT/GY), harness side and the LH No
steering wheel switch C2998-2, circuit VLN04 (VT/GY), REPAIR or INSTALL a new
harness side; and between the upper clockspring C218b-7, steering wheel harness.
circuit VLN04 (VT/GY), harness side and the RH steering INSTALL the driver air bag
wheel switch C2997-1, circuit VLN04 (VT/GY), harness side. module. REFER to Section
501-20B . TEST the system for
normal operation.

D6 CHECK THE STEERING WHEEL HARNESS GROUND
CIRCUIT FOR AN OPEN
PINPOINT TEST D: THE STEERING WHEEL CONTROL ILLUMINATION IS INOPERATIVE 5132

• Measure the resistance between the LH steering wheel switch Yes

C2998-4, circuit GD165 (BK), harness side and the INSTALL new steering wheel
clockspring C218b-2, circuit GD165 (BK), harness side; and controls as necessary. REFER to
between the RH steering wheel switch C2997-3, circuit Section 419-03 or Section
GD165 (BK), harness side and the clockspring C218b-2, 415-00 . TEST the system for
circuit GD165 (BK), harness side. normal operation.
No
REPAIR or INSTALL a new
steering wheel harness.
INSTALL the driver air bag
module. REFER to Section
501-20B . TEST the system for
normal operation.
Pinpoint Test E: One or More Switch Illumination Is Inoperative
Normal Operation
The Smart Junction Box (SJB) sends a Pulse Width Modulated (PWM) voltage to the dimmable components.
When the accessory delay relay is energized, voltage is supplied to the door lock control switches (Fusion),
roof opening panel switch and the cigar lighter.

• Ambient lighting/traction control switch (Fusion)
• Cigar lighter (MKZ)
• Luggage compartment lid release switch
• Door lock control switches (MKZ)
• Floor shifter
• Headlamp switch
• Memory set switch (MKZ)
• Message center switch (Fusion)
• Roof opening panel switch (if equipped)
• Window control switches (MKZ)
• Floor shifter
• SJB
PINPOINT TEST E: ONE OR MORE SWITCH ILLUMINATION IS INOPERATIVE


E1 CHECK THE VOLTAGE TO THE SINGLE
ILLUMINATION SOURCE
Yes
NOTE: If the headlamp switch is the inoperative For the instrument panel dimmer
source, unplug the headlamp switch connector to switch, window control switch, cigar
measure the illumination circuit voltage. Unplugging the lighter, door lock control switch, roof
connector causes the SJB to turn the exterior lights on opening panel switch, luggage
by default for 10 minutes, so it is unnecessary to turn the compartment lid release switch,
headlamp switch on. ambient lighting/traction control
switch, hazard flasher lamp switch, or
• Ignition OFF. floor shifter, INSTALL a new
• Disconnect: Inoperative Illumination Source. component in question. TEST the
• Place the headlamp switch in the PARKING LAMPS
ON position. For all others, GO to E2 .
• Increase the backlighting brightness to the highest
setting. No
• Measure the voltage between the inoperative REPAIR the voltage supply circuit in
illumination source, harness side and ground as follows: question for an open. TEST the system
Fusion
Component Connector-Pin Circuit

Ambient lighting/traction C2304-6 VLN04
control switch (Fusion) (VT/GY)
Luggage compartment lid C2269-3 VLN04
release switch (VT/GY)
Floor shifter C3233-4 VLN04
(VT/GY)
Hazard flasher lamp C2039-3 VLN04
switch (VT/GY)
Headlamp switch C205-1 VLN04
(VT/GY)
Instrument panel dimmer C2065-1 VLN04
switch (VT/GY)
Message center switch C253-3 VLN04
(VT/GY)
Roof opening panel C912-1 CBP41
switch (BU)
LH door lock switch C505-2 CBP41
(BU)
RH door lock switch C605-2 CBP41
(BU)
PINPOINT TEST E: ONE OR MORE SWITCH ILLUMINATION IS INOPERATIVE 5134

MKZ
Component Connector-Pin Circuit

Luggage compartment C2269-3 VLN37
lid release switch (BU/WH)
Floor shifter C3233-4 VLN37
(BU/WH)
Headlamp switch C205-1 VLN37
(BU/WH)
Instrument panel C2065-1 VLN37
dimmer switch (BU/WH)
Memory set switch C503-6 VLN37
(BU/WH)
LH door lock control C505-2 VLN37
switch (BU/WH)
RH door lock control C605-2 VLN37
switch (BU/WH)
LH front window C535a-7 VLN37
control switch (BU/WH)
RH front window C624-1 VLN37
control switch (BU/WH)
LH rear window control C701-4 VLN37
switch (BU/WH)
RH rear window control C819-4 VLN37
switch (BU/WH)
Cigar lighter C370-2 CBP41 (BU)
Roof opening panel C912-1 CBP41 (BU)
switch

E2 CHECK THE VOLTAGE TO THE SINGLE
ILLUMINATION SOURCE USING THE CONNECTOR
GROUND
Yes
• Measure the voltage between the inoperative INSTALL a new component in
illumination source connector, harness side as follows: question. TEST the system for normal
operation.
No
REPAIR the ground circuit in question
Fusion for an open. TEST the system for
normal operation.
Connector-Pin/ Connector-Pin/
Component Circuit Circuit
Headlamp C205-1 C205-8
switch
VLN04 (VT/GY) GD116 (BK/VT)
Message center C253-3 C253-6
switch
VLN04 (VT/GY) GD116 (BK/VT)

MKZ
Connector-Pin/ Connector-Pin/
Component Circuit Circuit
Headlamp C205-1 C205-8
switch
VLN37 (BU/WH) GD116 (BK/VT)
Memory set C503-6 C503-5
switch
VLN37 (BU/WH) GD126
(BK/WH)

SECTION 413-00: Instrument Cluster and Panel 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid
Illumination Workshop Manual
Instrument Panel Dimmer Switch
Fusion

2 5404338 Switch bezel
3 - Instrument panel dimmer switch electrical
connectors (part of 14401)
4 11961 Instrument panel dimmer switch
MKZ

3 - Instrument panel dimmer switch electrical
connectors (part of 14401)
Instrument Panel Dimmer Switch 5137

4 - Instrument panel dimmer switch

1. Remove the instrument panel side finish panel.
2. NOTE: The switch bezel assembly is removed by releasing tabs and pushing out from behind.
Release the tabs and remove the switch bezel assembly.
• Disconnect the electrical connectors.
3. Release the 2 tabs and remove the instrument panel dimmer switch from the switch bezel.
MKZ 5138
SECTION 413-01: Instrumentation, Message Center, 2012 Fusion, MKZ, Fusion Hybrid, MKZ
and Warning Chimes Hybrid Workshop Manual
Instrument Panel Cluster (IPC)
Fusion Non-Hybrid
NOTE: Non-select shift shown, select shift IPC similar.
Part
1 - Tachometer
2 - Malfunction Indicator Lamp (MIL)
3 - ABS warning indicator
4 - Traction control indicator
5 - LH turn indicator
6 - Traction control disabled indicator
7 - Speedometer
8 - Charging system warning indicator
9 - RH turn indicator
10 - Door/hood ajar warning indicator
11 - Low oil pressure warning indicator
12 - Powertrain malfunction (wrench) warning indicator
13 - Cruise control on indicator
14 - Fuel gauge
15 - Cruise control engaged indicator
16 - PRNDL display (displays PRNDM with select shift)
17 - Tire Pressure Monitoring System (TPMS) warning
indicator
18 - Engine coolant temperature gauge
19 - Grade assist indicator (without select shift)
20 - Air bag warning indicator
21 - Message center
Instrument Panel Cluster (IPC) 5139

22 - High beam indicator

23 - Safety belt warning indicator
25 - Brake warning indicator
MKZ Non-Hybrid

2 - Anti-theft indicator
3 - Tachometer
5 - Speedometer
6 - Traction control disabled indicator
7 - PRNDL display
9 - Fuel gauge
11 - TPMS warning indicator
12 - Select shift gear indicator
13 - Grade assist indicator (without select shift)
15 - area
18 - Message center
21 - Safety belt warning indicator
22 - MIL
Fusion Non-Hybrid 5140

Hybrid
NOTE: Fusion Hybrid enlighten display shown, MKZ Hybrid and other hybrid displays similar.

2 - PRNDL display
3 - Tachometer/EV gauge
4 - High voltage battery indicator
8 - Speedometer
12 - Fuel gauge
13 - Fuel efficiency gauge
14 - Efficiency information display
15 - Ready to drive indicator
16 - Anti-theft indicator (Fusion/Milan Hybrid only)
20 - Traction control disable indicator
21 - TPMS warning indicator
22 - MIL
23 - Odometer display
24 - Message center indicator display area
MyKey®
The MyKey® feature allows the customer to program a restricted driving mode that is tied to one or more
keys known as a MyKey®. When a MyKey® is in use, the IPC provides the following functions:
• The IPC continuously provides a periodical Belt-Minder® warning chime until the driver and
passenger safety belts are buckled. When the Belt-Minder® is issued, the ACM is muted and the
Hybrid 5141
message center displays BUCKLE UP TO UNMUTE RADIO.
• If the MyKey® speed limiter feature is turned on and the vehicle speed approaches 130 km/h (80
mph), the message center displays VEHICLE NEAR TOP SPEED along with a chime.
• If the MyKey® speed limiter feature is turned on and the vehicle speed reaches 130 km/h (80 mph),
the message center displays TOP SPEED MYKEY SETTING along with a chime.
• If the speed warning is selected at one of the pre-set values (75, 90, 105 km/h [45, 55, 65 mph]) and
the vehicle approaches the pre-set speed, the message center displays CHECK SPEED DRIVE
SAFELY along with a chime.
• If the traction control always on feature is turned on and the MyKey® driver presses the traction
control switch to disable traction control, the message center displays ADVDTAC ON MYKEY
SETTING.
• At 120 km (75 miles) of remaining fuel, the IPC illuminates the low fuel indicator (if equipped) and
the message center displays the appropriate Distance To Empty (DTE) along with a chime.
• MyKey® miles driven by the MyKey® user can be found in the information d
• The number of MyKey® programmed and administrator keys can be found in the information and
system check displays.
• The parking aid, Blind Spot Information System (BLIS®) Cross Traffic Alert (CTA) and collision
avoidance warning menus are disabled in the message center to force these features always on.
When an administrator key is in use, the IPC provides the following functions:
• The message center provides a menu that guides the user to create a MyKey® programmed key.
When the maximum MyKey® limit is reached, the MyKey® creation menu is no longer available.
• The message center provides menus for setting 4 optional MyKey® features:
♦ MyKey® 80 MPH speed limiter
♦ MyKey® pre-selected speed warning
♦ MyKey® radio volume limiter
♦ Traction control on/off
• The message center provides a menu to clear all MyKey® programmed keys at once.
• MyKey® mileages driven by the MyKey® user can be found in system check function of the message
center.
• The number of MyKey® and administrator keys can be found in the system check function of the
message center.
Refer to Section 419-01B for additional information on the MyKey® features.
Non-Hybrid
The Instrument Panel Cluster (IPC) contains gauges, informational indicators, warning indicators, message
center and message center indicators (MKZ only) that are designed to provide the driver with a system status
and to er that certain conditions exist in the vehicle.
The IPC uses a message center display area for basic informational items such as the odometer, trip odometer,
text-based messages and for message center warning indicator displays.
Startup (Welcome) Mode
The IPC provides a startup mode also known as a welcome strategy. When the vehicle receives a Remote
Keyless Entry (RKE) request, the IPC illuminates the gauge pointers and graduation bars. When the key is
inserted into the ignition switch, the IPC illuminates only the graduation bars. When the ignition is placed into
the RUN or START position, the IPC begins its prove-out stage.
During the prove-out stage, the IPC sweeps then zeros all gauges while illuminating all LED indicators for a
predetermined time.
Hybrid 5142
Gauges
Gauges provide information to the driver indicating the status of systems. The systems that use gauges are as
follows:

• Engine rpm
• Fuel level
• Vehicle speed
Informational Indicators
Informational indicators provide information to the driver of conditions that exist in the vehicle. The
informational indicators are grouped into the following systems/subsystems:
• Engine/powertrain control
♦ All-Wheel Drive (AWD)
♦ Electronic Throttle Control (ETC)
♦ Fuel level
♦ Malfunction Indicator Lamp (MIL)
♦ Transaxle
• Lighting
♦ High beam
♦ Turn signal
• Vehicle control
♦ Anti-theft
♦ Cruise control
♦ Traction control
Warning Indicators
Warning indicators provide information to the driver of conditions that could potentially cause personal injury
or alter vehicle performance. The warning indicators are grouped into the following systems/subsystems:
♦ Charging system
♦ Low engine oil pressure
• Occupant/driver safety
♦ Door/hood ajar
♦ Safety belt
♦ Tire Pressure Monitoring System (TPMS)
♦ Supplemental Restraint System (SRS) (air bag)
• Vehicle control
♦ ABS
♦ Brake system
Message Center Warning Indicators (MKZ Only)
Message center warning indicators illuminate in the message center and replace the typical indicator and
warning lamps using the same iconic representation that are typically used as indicators or warning indicators
in the IPC . When multiple warnings exist, the message center warning indicators rotate through each display
until each condition has been corrected. The systems that use message center warning indicators include:
Hybrid 5143
♦ Charging system
♦ Low engine oil pressure
♦ Low fuel
♦ Door/Hood ajar
Hardwired Inputs
The hardwired inputs are provided from the following systems or components:
• Compass
• Engine oil pressure switch
• Fuel level
• Message center switch
• Park detect
• Passive Anti-Theft System (PATS) transceiver
• Traction control disable switch
Network Messaged Inputs
Module messaging is becoming the standard for sending and receiving information required to operate the
IPC . For a complete list of module messages with the message origination sources, refer to Section 418-00 .
The status and information messages that the IPC requires from other vehicle inputs are grouped into the
following systems/subsystems:
• ABS
♦ Anti-lock braking
• Base brake system
♦ Brake fluid level status
♦ Parking brake status
• Lighting system
♦ LH/RH turn
♦ High beam
• Powertrain
♦ Charging
♦ Engine emission system
♦ Engine rpm
♦ Engine temperature
♦ Grade assist (without select shift)
♦ Transmission range
♦ Vehicle speed
• SRS
• TPMS
Hybrid
The hybrid Instrument Panel Cluster (IPC) contains gauges, informational indicators, warning indicators,
message center and message center indicators that are designed to provide the driver with a system status and
to alert the driver that certain conditions exist in the vehicle. The instrument cluster uses digital displays for
all non-text information except the speedometer. The speedometer is the only analog gauge used.
The IPC uses a message center display area for basic informational items such as the odometer, trip odometer,
Hybrid 5144
text-based messages and message center warning indicator displays.
Startup (Welcome) Mode
The IPC provides a startup mode also known as a welcome strategy. When the vehicle receives a Remote
Keyless Entry (RKE) request, the IPC begins the wake up sequence by illuminating the display areas on the
RH and LH sides of the speedometer in ice blue followed by the grass and cloud image on each display area
when the driver door is opened.
When the key is placed into the ignition, the speedometer pointer illuminates for approximately 30 seconds or
until the key is transitioned to the RUN position.
Once the key is transitioned to the RUN position, the IPC continues the startup sequence through a series of
stages that sweep and zero the speedometer, while illuminating the remaining gauges and digital displays
starting at the center and moving outward. During this phase, the digital gauges sweep from zero or the lowest
position to the highest position then return to display the current input value. The IPC also carries out the bulb
prove-out during this phase of the startup mode.
As part of the startup mode, the IPC displays the Press Info to View Demo for the first 800 km (500 miles).
From 800 km (500 miles) to 1,600 km (1,000 miles), the IPC displays Demo and Tutorial Can Be Started
Within SETUP Mode . After 1,600 km (1,000 miles), the text disappears from the startup mode but the demo
mode remains selectable through the setup menu.
Gauges
All gauges are digital displays except the speedometer which uses an analog gauge. Gauges provide
information to the driver indicating the status of systems. The systems that use gauges are as follows:
• Electric vehicle
• Engine rpm
• Fuel efficiency
• Fuel level
• High voltage battery
• Vehicle speed
Informational Indicators
Informational indicators provide information to the driver of conditions that exist in the vehicle. The
informational indicators are grouped into the following systems/subsystems:
♦ Malfunction Indicator Lamp (MIL)
♦ Hybrid ready
• Lighting
♦ High beam
♦ Turn signal
• Vehicle control
♦ Anti-theft
♦ Cruise control
Warning Indicators
Hybrid 5145
Warning indicators provide information to the driver of conditions that could potentially cause personal injury
or alter vehicle performance. The warning indicators are grouped into the following systems/subsystems:
♦ Safety belt
♦ Tire Pressure Monitoring System (TPMS)
♦ Supplemental Restraint System (SRS) (air bag)
• Vehicle control
♦ ABS
♦ Brake system
Message Center Warning Indicators
Message center warning indicators illuminate in the message center and replace the typical indicator and
warning lamps using the same iconic representation that are typically used as indicators or warning indicators
in the IPC . When multiple warnings exist, the message center warning indicators rotate through each display
until each condition has been corrected. The systems that use message center warning indicators include:
♦ Charging system
♦ Electronic Throttle Control (ETC)
♦ High voltage battery
♦ Fuel level
♦ Motor temperature
♦ Oil pressure
♦ Transaxle
♦ Door ajar
♦ Trunk ajar
Hardwired Inputs
The hardwired inputs are provided from the following systems or components:
• Compass
• Fuel level
• Message center switch
• Park detect
• Passive Anti-Theft System (PATS) transceiver
• Traction control disable switch
Network Messaged Inputs
Module messaging is becoming the standard for sending and receiving information required to operate the
IPC . For a complete list of module messages with the message origination sources, refer to Section 418-00 .
The status and information messages that the IPC requires from other vehicle inputs are grouped into the
following systems/subsystems:
• ABS
♦ Anti-lock braking
Hybrid 5146
• Base brake system
♦ Brake fluid level status
♦ Parking brake status
• Lighting system
♦ LH/RH turn
♦ High beam
• Powertrain
♦ Charging system
♦ ETC
♦ High voltage battery
♦ Engine emission system
♦ Engine rpm
♦ Motor temperature
♦ Transaxle
♦ Vehicle speed
• SRS
• TPMS
Hybrid 5147
Information And Message Center
The message center is a fixed format display, integrated into the Instrument Panel Cluster (IPC). The message
center functions are controlled by the message center switch. The message center displays important vehicle
information by constantly monitoring different vehicle systems and informs the driver of vehicle operations,
notifying the driver of potential vehicle problems by displaying a warning message pertaining to the system in
which a fault has been detected.
The message center switch is located as follows:
• For MKZ, in the Front Controls Interface Module (FCIM).

• For hybrid and Fusion non-hybrid, on the LH side of the steering wheel incorporated into the steering
wheel switch.
The message center provides the following features:
• Information displays
• Setup displays
• System check messages
• System warning messages
The message center information is selected through a set of 3 buttons:
• INFO
• SETUP
• RESET
Message Center Configuration
The message center has the capability to configure items such as units (English or metric), autolamp delay, to
enable/disable a variety of options such as autolock, auto-unlock and easy entry/easy exit (if equipped).
On configurable items such as autolock, auto-unlock or easy entry/easy exit, the message center indicates the
appropriate selection (ON/OFF) by bracketing the selection. For example, if the driver selects the autolock
feature on, the message would display as follows: AUTOLOCK â ©ON> OFF. If the driver selects the
autolock off, the message would display as follows: AUTOLOCK ON â ©OFF>.
Oil Change Minder
NOTE: On early build vehicles, the PCM uses time and distance calculations stored in Keep Alive Memory
(KAM) in the PCM to help determine the oil change minder status. If the PCM KAM is reset or lost for any
reason (battery disconnect, PCM disconnect or dead battery), the oil change minder is disabled and the oil life
reset procedure needs to be carried out through the message center to re-enable the oil minder function.
The message center provides an oil change minder to inform the driver that an oil change is required. The
duration of the interval between oil changes is calculated in the PCM based an a maximum mileage of 16,093
km (10,000 miles) or 1 year for normal driving. The PCM calculates and provides an oil life status message to
the IPC . The IPC further converts the remaining oil life using the driver's configured oil life start value and
displays the oil life percentage, indicating the remaining oil life. The oil change minder can be reset at any
time by the driver. Refer to Message Center Configuration in this section.
Information And Message Center 5148

Oil Life and Oil Life Start Value
The oil life is displayed in percentages. The oil life start value is used to increase or decrease the starting point
of the oil life. The oil life start value can be changed back to the maximum of approximately 16,093 km
(10,000 miles) if the value was previously changed or to lower the value by 10% increments down to 10%.
Each 10% reduction lowers the oil life in both mileage and time (days).
Compass Display
Vehicles Without Navigation
The compass signal originates from the compass module, which is integrated into the auto-dimming interior
mirror.
The compass reading is incorporated into the Front Display Interface Module (FDIM).
The vehicle heading is displayed as a 1 or 2 character display located in the upper RH side of the FDIM and
indicates the current direction of the vehicle (N, NE, E, SE, S, SW, W, or NW). The compass continuously
re-calibrates due to changes in the magnetic field and remains accurate during most driving conditions.
On Fusion, the Front Controls Interface Module (FCIM) buttons that allow the driver to operate (change) the
calibration and zone setting procedures are located below the FDIM .
On MKZ, the buttons that allow the driver to operate (change) the calibration and zone setting procedures are
located on the FDIM .
The compass display is on with the ignition in the ON or START position. When the ignition is first turned to
the ON or START position, there is a momentary delay of approximately 6 seconds before the compass
display illuminates. If the battery saver has been activated and the ignition is turned to ON or START, the
momentary delay before the compass display illuminates is approximately 3 seconds. The compass display
turns off as soon as the ignition is turned to the OFF or ACC position.
Vehicles With Navigation
The compass signal originates from the Global Positioning System (GPS) antenna. No calibration or zone
adjustment is available, as the compass heading is based on the GPS signal. Refer to Section 415-00 for
information on the GPS signal.
Compass Accuracy (Without Navigation)
Driving near power lines, or driving in the area of large iron or steel structures can temporarily change the
compass heading. If the compass remains inaccurate after driving near such objects, calibrate the compass.
Refer to Compass Calibration in this section.
Most geographic areas (zones) have a magnetic north compass point that varies slightly from the northerly
direction on maps. This variation is 4 degrees between the adjacent zones and becomes noticeable as the
vehicle crosses multiple zones. A correct zone setting eliminates the error. Refer to Compass Zone
Adjustment in this section.
Fusion and MKZ (Non-Hybrid)
Information Displays (INFO button)
The information displays are non-timed modes. The selected mode remains on until the driver presses a
message center button to change the mode or it is overridden by another mode. The information display
Vehicles Without Navigation 5149

modes are:
• Odometer
• Trip odometer A or B
• MyKeyÂ® miles
• Distance To Empty (DTE)
• Average fuel economy
• Instantaneous fuel economy
• Trip elapsed drive time A or B
• Blank display
Setup Displays (SETUP button)
The setup displays are timed modes and terminate after a finite interval. The setup display modes are:
• System check
• Oil life
• Units (English/metric)
• Autolamp
• Autolock
• Auto-unlock
• Blind Spot Information System (BLISÂ®) (if equipped)
• Cross Traffic Alert (CTA) system (if equipped)
• Easy entry/easy exit (MKZ only)
• Create MyKeyÂ®
• MyKeyÂ® setup
• Clear MyKeyÂ®
• Parking aid (reverse sensing) (if equipped)
• Language
System Check Displays (RESET button)
By pressing the RESET button on the message center switch, the message center cycles through each of the
system check displays being monitored. For each of the monitored systems, the message center indicates
either an OK message or a warning message for 2-4 seconds.
The system check provides a check of the following systems:
• XXX% oil life

• All doors closed
• Trunk closed
• BLISÂ® (if equipped)
• CTA system (if equipped)
• Brake system
• Fuel level
System Warning Messages
The system warning messages alert the driver to possible problems or malfunctions in the vehicle operating
systems. The message center displays the last selected feature if there are no additional warning messages.
Once a warning message has been displayed, the message must be acknowledged to allow full functionality of
the message center. Press the RESET button (base message center) or the OK button (optional message
center) to acknowledge and clear the warning message.
Compass Accuracy (Without Navigation) 5150

The warning messages are divided into 3 basic categories:
• Cannot be cleared until the condition is corrected.

• Reappears 10 minutes after pressing the select/reset button.
• Reappears if the condition clears then reoccurs within the same ignition ON-OFF cycle.
When the IPC receives a request to display an informational warning message or a fault condition warning
message, the message center may display one of the following warning messages:
Body
• BLIND SPOT NOT AVAILABLE (if equipped)

• BLIND SPOT SYSTEM FAULT (if equipped)
• CROSS TRAFFIC NOT AVAILABLE (if equipped)
• CROSS TRAFFIC SYSTEM FAULT (if equipped)
• DRIVER DOOR AJAR
• INTKEY COULD NOT PROGRAM (displayed when an attempt is made to program an invalid key
or more than the maximum number of keys allowed by the Remote Keyless Entry (RKE) system).
• PASSENGER DOOR AJAR
• REAR LEFT DOOR AJAR
• REAR RIGHT DOOR AJAR
• REMOVE OBJECTS NEAR PASS SEAT
• SENSOR BLOCKED SEE MANUAL (if equipped)
• TO STOP ALARM START VEHICLE
• TRUNK AJAR
• VEHICLE COMING FROM LEFT (if equipped)
• VEHICLE COMING FROM RIGHT (if equipped)
Chassis
• BRAKE FLUID LEVEL LOW

• CHECK BRAKE SYSTEM
• CHECK PARK AID (if equipped)
• LOW TIRE PRESSURE
• PARK BRAKE ENGAGED
• POWER STEERING ASSIST FAULT (2.5L and 3.0L only)
• SERVICE ADVANCETRAC
• SERVICE POWER STEERING (2.5L and 3.0L only)
• SERVICE POWER STEERING NOW (2.5L and 3.0L only)
• TIRE PRESSURE MONITOR FAULT
• TIRE PRESSURE SENSOR FAULT
MyKeyÂ®
• KEY COULD NOT PROGRAM

• VEHICLE SPEED 130 KM/H (80 MPH) MAX
• MYKEY ACTIVE DRIVE SAFELY
• SPEED LIMITED TO 130 KM/H (80 MPH)
• CHECK SPEED DRIVE SAFELY
• VEHICLE NEAR TOP SPEED
• TOP SPEED MYKEY SETTING
• BUCKLE UP TO UNMUTE AUDIO
• ADVTRAC ON MYKEY SETTING

Powertrain
• CHECK AWD (if equipped)

• CHECK FUEL FILL INLET
• FUEL LEVEL LOW
• OIL LIFE CHANGE SOON
• OIL CHANGE REQUIRED
Service Procedure Displays
In addition to the warning messages, the message center provides messages that are displayed during repair
procedures to indicate certain states of a procedure. The following are the service repair procedures displayed
in the message center:
Tire Pressure Monitoring System (TPMS) Tire Training

• TIRES NOT TRAINED-REPEAT
• TRAIN LEFT FRONT TIRE
• TRAIN LEFT REAR TIRE
• TRAIN RIGHT FRONT TIRE
• TRAIN RIGHT REAR TIRE
• TRAINING COMPLETE
Hybrid
There are two basic viewing areas used for control and dissemination of the information related to the
message center functions. The LH side of the Instrument Panel Cluster (IPC) displays the primary navigation
and selections available. The RH side of the IPC displays instructions that assist the operator with controlling,
selecting and maneuvering through the message center functions. The RH side only displays the instructions
when the vehicle is stopped and returns to the IPC indication mode while the vehicle is in motion.
Information Displays (INFO button)
The information displays are non-timed modes. The selected mode remains on until the driver presses the
INFO button to change the display. The information display modes are:
• Trip odometer A or B
• Average fuel economy
• Trip elapsed drive time A or B
• MyKeyÂ® miles
• Blank display
Setup Displays (SETUP button)
The setup displays are timed modes and terminate after a finite interval. To enter the setup menu, press the
SETUP button once then repeatedly press the SETUP button to scroll through and select an item in the setup
menu. The message center highlights the selected item in the LH side of the setup menu.
With the desired item highlighted, press the RESET button to select the item and move to the RH side of the
setup menu. A check mark is displayed next to the current selection.
The setup displays are as follows:
• Display settings
• Vehicle settings

• System check
• Demo
• Tutorials
• Resets
Display Settings
With the display settings selection highlighted, press the RESET button to move to the RH side of the display
settings selection of the setup menu (a check mark is displayed next to the current selection). Press the SETUP
button to scroll through and select the item in the RH menu then press the RESET button to select the item.
The display settings are as follows:
• Display mode
♦ Inform
♦ Enlighten
♦ Engage
♦ Empower
• Fuel economy
♦ On
♦ Off
• Efficiency gauge
♦ Efficiency leaves
♦ FE history graph
♦ None
• FE History Length
♦ 10 minutes
♦ 20 minutes
♦ 60 minutes
• Language
♦ English
♦ French
♦ Spanish
• Units
♦ English
♦ Metric
Efficiency Leaves
The 2 fuel efficiency display modes for the efficiency gauge provide similar information but in an entirely
different format. Both display modes provide the average miles per gallon at the top of the display and the
distance to empty at the bottom of the display. The efficiency leaves displays a leaf and vine display that
changes as the vehicle driving efficiency changes. As driving efficiency increases, the efficiency leaves
display adds more leaves and vines. The history graph can be displayed using 10, 20 or 60 minute intervals
and is updated every 1, 2 or 6 minutes respectively. Each new average is added to the left side of the graph
shifting the last update to the right.
Vehicle Settings
With the vehicle settings selection highlighted, press the RESET button to move to the RH side of the vehicle
settings selection of the setup menu (a check mark is displayed next to the current selection). Press the SETUP
button to scroll through and select the item in the RH menu then press the RESET button to select the item.
The vehicle settings are as follows:

• Autolamp
♦ 0 seconds
♦ 10 seconds
♦ 20 seconds
♦ 30 seconds
♦ 60 seconds
♦ 90 seconds
♦ 120 seconds
♦ 180 seconds
• Auto unlock
♦ On
♦ Off
• Autolock
♦ On
♦ Off
• Blind Spot (if equipped)
♦ On
♦ Off
• Cross Traffic Alert (if equipped)
♦ On
♦ Off
• Oil Life
♦ Set to 100%
♦ Set to 90%
♦ Set to 80%
♦ Set to 70%
♦ Set to 60%
♦ Set to 50%
♦ Set to 40%
♦ Set to 30%
♦ Set to 20%
♦ Set to 10%
• Rear Park Aid (if equipped)
♦ On
♦ Off
MyKeyÂ® Settings
• Create MyKeyÂ®
• MyKeyÂ® AdvTrac
♦ Manual
♦ Always on
• MyKeyÂ® speed
♦ 130 km/h/80 mph
♦ Off
• MyKeyÂ® chimes
♦ Off
♦ 75 km/h/45 mph
♦ 90 km/h/55 mph
♦ 105 km/h/65 mph
• MyKeyÂ® volume
♦ Limited
♦ Not limited
• Clear MyKeyÂ®

System Check
With the system check selection highlighted, press the RESET button to move to the RH side of the system
check selection of the setup menu. Press RESET to start the system check.
The system check menu is as follows:
• Oil life
• Electric drive
• Charging system
• Door ajar
• Trunk ajar
• Electronic Power Assist Steering (EPAS)
• Blind spot (if equipped)
• Cross traffic alert (if equipped)
• Brake system
• Brake fluid
• Parking brake
• Tire pressure
• Passenger seat
• Parking aid
• Fuel fill inlet
• Fuel level (mi/km)
• MyKeyÂ® used
• MyKeyÂ®(s) programmed
• Admin key(s) programmed
System Warning Messages
System warnings alert the operator to possible problems or malfunctions in the vehicle operating system.
When multiple warnings are displayed, the message center cycles all the warnings by displaying each one for
several seconds. The system warning messages are displayed in the LH side of the IPC .
All warning messages are considered as active or non-active. Active warnings are those where the monitored
system detects a current fault condition. Once the fault condition is corrected, the warning then becomes
non-active. Both active and non-active warnings can be reset but if the warning is active, it continues to be
displayed once it is reset.
All new warnings along with any associated message center warning indicators are displayed in a large format
for 2 seconds and cannot be reset until the 2 second time has elapsed. Once the 2 seconds has elapsed, the
warning can be reset by pressing the RESET button. Once the RESET button is pressed, the warning is
considered an old warning and is displayed in a smaller format. If there are multiple warnings present, each
warning displays (2 seconds for new warnings and 4 seconds for old warnings) in the order the message center
received the warnings.
The message center displays the temperature gauge and PRNDL once all messages are reset and there are no
more new warning messages. This allows full functionality of the message center by pressing the message
center switch RESET button to clear the warning message. Warning messages that have been reset are divided
into 2 categories where the message:
• Returns every 10 minutes

• Returns every key cycle
When the IPC receives a request to display an informational warning message or a fault condition warning

message, the message center may display one of the following warning messages:
Body
• BLIND SPOT NOT AVAILABLE (if equipped)

• BLIND SPOT SYSTEM FAULT (if equipped)
• CROSS TRAFFIC NOT AVAILABLE (if equipped)
• CROSS TRAFFIC SYSTEM FAULT (if equipped)
• DRIVER DOOR AJAR
• INTKEY COULD NOT PROGRAM (displayed when an attempt is made to program an invalid key
or more than the maximum number of keys allowed by the Remote Keyless Entry (RKE) system).
• PASSENGER DOOR AJAR
• REAR LEFT DOOR AJAR
• REAR RIGHT DOOR AJAR
• REMOVE OBJECTS NEAR PASS SEAT
• SENSOR BLOCKED SEE MANUAL (if equipped)
• TO STOP ALARM START VEHICLE
• TRUNK AJAR
• VEHICLE COMING FROM LEFT (if equipped)
• VEHICLE COMING FROM RIGHT (if equipped)
Chassis
• BRAKE FLUID LEVEL LOW

• CHECK BRAKE SYSTEM
• CHECK PARK AID (if equipped)
• LOW TIRE PRESSURE
• PARK BRAKE ENGAGED
• POWER STEERING ASSIST FAULT
• SERVICE ADVANCETRAC
• SERVICE POWER STEERING
• SERVICE POWER STEERING NOW
• TIRE PRESSURE MONITOR FAULT
• TIRE PRESSURE SENSOR FAULT
MyKeyÂ®
• KEY COULD NOT PROGRAM

• VEHICLE SPEED 130 KM/H (80 MPH) MAX
• MYKEY ACTIVE DRIVE SAFELY
• SPEED LIMITED TO 130 KM/H (80 MPH)
• CHECK SPEED DRIVE SAFELY
• VEHICLE NEAR TOP SPEED
• TOP SPEED MYKEY SETTING
• BUCKLE UP TO UNMUTE AUDIO
• ADVTRAC ON MYKEY SETTING
Powertrain
• STOP SAFELY NOW

• HIGH ENGINE TEMPERATURE
• HIGH MOTOR TEMPERATURE
• CHECK AWD (if equipped)
• CHECK FUEL FILL INLET

• FUEL LEVEL LOW
• OIL LIFE CHANGE SOON
• OIL CHANGE REQUIRED
Service Procedure Displays
In addition to the warning messages, the message center provides messages that are displayed during repair
procedures to indicate certain states of a procedure. The following are the service repair procedures displayed
in the message center:
Tire Pressure Monitoring System (TPMS) Tire Training

• TIRES NOT TRAINED-REPEAT
• TRAIN LEFT FRONT TIRE
• TRAIN LEFT REAR TIRE
• TRAIN RIGHT FRONT TIRE
• TRAIN RIGHT REAR TIRE
• TRAINING COMPLETE

Warning Chimes
The warning chimes are designed to provide the driver with an audible warning that acts as a supplemental
alert. The only deviation from this strategy is the air bag chime which is used to alert the driver that the
primary alerting system (air bag warning indicator) does not operate. The Instrument Panel Cluster (IPC)
controls all warning chimes based on messages received from external modules.
The warning chime system consists of the following:
• IPC
• Key-in-ignition warning switch (part of the ignition switch)
• Restraints Control Module (RCM)
• SJB
The following chimes are controlled by the IPC :
• Air bag warning

• Belt-Minder®
• Door ajar
• Headlamps on
• Hybrid electric vehicle engine off reminder
• Key-in-ignition
• Message center
• Parking brake on
• Perimeter alarm
• Safety belt warning
• ServiceRoll Stability Control (RSC®) warning
• Turn signal/hazard
• Turn signal left on
• Memory feedback (if equipped)
Warning Chimes 5158

Warning Chimes 5159

Instrumentation, Message Center and Warning Chimes
Special Tool(s)
Fluke 77-1V Digital Multimeter

Instrument Gauge System Tester


Flex Probe Kit
NUD105-R025D or equivalent
NOTE: When installing a new Instrument Panel Cluster (IPC), it is necessary to upload the module
configuration to the scan tool. Following installation of the IPC , download the module configuration from the
scan tool into the new IPC . Refer to Section 418-01 to carry out the Programmable Module Installation
(PMI). It is also necessary to carry out a parameter reset procedure whenever a new IPC or PCM (non-hybrid)
or Transmission Control Module (TCM) (hybrid) is installed. Refer to Section 419-01B .
The IPC utilizes a microprocessor to control the gauge, indicator, message center and warning chime
functions. Data is sent to the IPC over the Medium Speed Controller Area Network (MS-CAN) and the High
Speed Controller Area Network (HS-CAN) bus lines and through hardwired circuitry from individual
components. The IPC uses each input to output an action to the gauges or indicators.
It is very important to understand:
• where the input originates.

• all the information necessary in order for a feature to operate.
• which module(s) receive(s) the input or command message.
• does the module which received the input control the output of the feature, or does it output a message
over the communication network to another module.
• which module controls the output of the feature.
Instrumentation, Message Center and Warning Chimes 5160

IPC Gateway Function
The IPC acts as a gateway module by receiving information in one format and transmitting it to other modules
using another format. For example, the IPC receives the vehicle speed data from the PCM over the HS-CAN ,
converts the data into an MS-CAN message and sends (gateways) the message to other network modules such
as the HVAC module, the Audio Front Control Module (ACM) and the SJB . This enables network
communication between modules that do not communicate using the same network ( HS-CAN or the
MS-CAN ).
IPC Network Messages
The IPC uses input messages from other modules to control the gauges, informational indicators and warning
indicators over the communication networks. If a required message is missing or invalid for less than 5
seconds, the gauge or indicator that requires the message remains at the last commanded state based upon the
last known good message. For example, if the brake status message is missing for less than 5 seconds and the
brake warning indicator was on, the indicator remains in the on state until the next good message is received.
If the message remains missing or invalid for greater than 5 seconds, the IPC sets a U-code DTC and the
output becomes a default action for the indicator or gauge. Each indicator or gauge utilizes a different default
strategy depending on the nature of the indication. Refer to the normal operation descriptions located before
each individual pinpoint test for further description of the default action specific to each indicator or gauge. If
the messaged input to the cluster returns at any time, the normal function of the gauge or indicator resumes.
NOTE: Whenever a network message is suspected as missing and confirmed by a missing message DTC
(U-code), it is important to look for other symptoms that may also be present in the IPC and throughout the
vehicle. Once a DTC is set in the IPC , it may be helpful to review the complete message list available in
Section 418-00 to see what other modules also rely on the same message and run the self-test for those
modules. If the message is missing from other modules, the same DTC may also be set in those modules.
Confirmation of missing messages common to multiple modules may indicate that the originating module is
the source of the concern or the communication network may be experiencing some problems.
IPC Configuration
The IPC contains items that are configurable. Configurable items include customer preference items, which
can also be set with a scan tool. The remaining configurable items can be set only through the PMI procedure
or by using As-Built data. Refer to Section 418-01 .
IPC Configuration Parameters
Customer Preference Parameter As-Built Parameter

- ABS
- Adaptive headlamps
- Average fuel economy metric display type
- Autolamp delay
- Autolock
- Auto-unlock
- Belt-Minder®
- Cluster plant mode
- Compass
- Cross traffic
IPC Gateway Function 5161

- Default oil life

- Easy entry/easy exit
- Engineering test mode
- Electronic Power Assist Steering (EPAS)
- English/metric default (Units)
- Flex-fuel
- Fuel tank size
- Gallon display type
-
- Key-in-ignition warning chime
- Language
- MyKey®
- Navigation
- Number of fuel senders
- Number of fuel tanks
- Overspeed warning chime (gulf coast countries)
- Rear park aid
- Reverse mirror
- Roll Stability Control (RSC®) chime
- Transmission Control Module (TCM) (stand alone/integrated TCM
-PCM
- Select shift
- Side detect
- Speedometer calibration (Europe/North America)
- Traction control/interactive vehicle dynamics/ RSC®
Tire Pressure Monitoring System
(TPMS)
- Welcome
- 2-Wheel Drive (2WD)/Four-Wheel Drive (4WD)/All-Wheel Drive
(AWD)
IPC Configuration Parameters - Hybrid
Customer Preference
Parameter As-Built Parameter
- ABS
- Average fuel economy metric display type
- Autolamp delay
- Autolock
- Auto-unlock
- Belt-Minder®
- Cluster plant mode
- Compass
IPC Configuration 5162

- Cross traffic
- Daytime illumination
- Default oil life
- Electronic stability control/Roll Stability Control (RSC®) warning
English/metric default (Units)
- Flex-fuel
- Fuel tank size
- Gallon display type
- IKT
- Key-in-ignition warning chime
- Language
- MyKey®
- Navigation
- Number of fuel senders
- Number of fuel tanks
- Overspeed warning chime (gulf coast countries)
- Park aid front
- Park aid rear
- Side detect
- Speedometer calibration
- Traction control/interactive vehicle dynamics/
- Transmission Control Module (TCM)
- Tire Pressure Monitoring System (TPMS)
- Transmission type (manual/automatic)
- Vehicle brand (Ford/Mercury/Lincoln)
- 2-Wheel Drive (2WD)/Four-Wheel Drive (4WD)/All-Wheel Drive
(AWD)
IPC Software Flashing
The IPC is capable of receiving updated software after the end of line production. This software updating is
called software flashing and is only carried out when a Technical Service Bulletin (TSB) provides the
direction to do so. Follow all instructions on the TSB when flashing the IPC .
IPC Prove-Out
The IPC carries out a display prove-out to verify that all module controlled warning/indicator lamps and
monitored systems are g correctly within the IPC . When the ignition is in the ON mode with the engine off,
the indicators illuminate to prove-out according to the following table:
Non-Hybrid
Indicator
Indicator Type Prove-Out Duration
IPC Software Flashing 5163

ABS Warning 3 seconds

Air bag Warning 6 seconds
Anti-theft indicator Informational 3 seconds
Brake Warning 3 seconds
Charging system Informational Engine start up
Door/hood ajar Informational No prove-out
Grade assist (without select Informational No prove-out
shift)
High beam Informational No prove-out
Low engine oil pressure Warning Engine startup
Malfunction Indicator Lamp Warning Engine startup
(MIL)
Powertrain malfunction Warning 3 seconds
(wrench)
RH/LH turn signals Informational No prove-out
Safety belt Warning 65 seconds if the safety belt is unbuckled, turns off when
the safety belt is buckled
Cruise control engaged Informational No prove-out
Cruise control on Informational No prove-out
Tire Pressure Monitoring Warning 3 seconds
System (TPMS)
Traction control Informational 3 seconds
Traction control disabled Informational 3 seconds
Hybrid
Indicator
Indicator Type Prove-Out Duration
ABS Warning 3 seconds
Air bag Warning 6 seconds
Anti-theft indicator Informational 3 seconds
Brake Warning 3 seconds
High beam Informational No prove-out
Malfunction Indicator Lamp Warning Engine startup
(MIL)
Ready to drive Informational No prove-out
RH/LH turn signals Informational No prove-out
Safety belt Warning 65 seconds if the safety belt is unbuckled, turns off when
the safety belt is buckled
Cruise control Informational No prove-out
Tire Pressure Monitoring Warning 3 seconds
System (TPMS)
Traction control Informational 3 seconds
Traction control disabled Informational 3 seconds
IPC Prove-Out 5164

Information And Message Center
The message center is an integral part of the IPC that receives and acts upon much of the same information
that is input and used to operate the IPC gauges, informational indicators, warning indicators and warning
chimes. For all vehicles except hybrid, the message center is a 2-line display located in the center of the IPC .
On hybrid vehicles, the message center is split between the LH and RH side of the IPC with the controls
displayed on the LH side and instructions displayed on the RH side. The hybrid message center also uses
message center indicators either as stand alone indications or combined with text messages and are displayed
in the LH display area.
All message center functions are controlled by a 3-button message center switch, which is hardwired to the
IPC . The message center switch consists of 3 buttons and a resistor ladder with a different resistor associated
with each switch button. The IPC sends out a reference voltage to the message center switch and monitors the
voltage drop that results from the voltage flowing through the resistor when a message center button is
pressed. The voltage drop will vary depending upon the resistance of each button, providing a specific
indication to the IPC which switch is pressed.
NOTE: Compass zone adjustment and calibration proceedures are only applicable to vehicles without
navigation. For vehicles with navigation, refer to Section 415-00 .
Compass
The compass display (located in the Front Display Interface Module (FDIM)) receives battery voltage from
the SJB . The compass module (integral to the auto-dimming interior mirror) provides hardwired vehicle
directional inputs to the Instrument Panel Cluster (IPC), which sends the compass information to the FDIM
over the Medium Speed Controller Area Network (MS-CAN). The compass is capable of self-calibrating.
This decreases the need to manually set the compass. If the compass is displaying a heading (and not
displaying the C or CAL indicator), the compass is in auto-calibration mode. In this mode, the compass
automatically calibrates for changes in vehicle magnetics over the life of the vehicle. This auto-calibration
mode makes sure the compass heading is always accurate. If the compass displays the C or CAL indicator for
an extended period of time (longer than 5 seconds), this indicates the compass has been placed in the manual
calibration mode and therefore, requires manual calibration. Refer to Compass Calibration in this section.
Warning Chimes
The IPC uses inputs that are hardwired to individual components and messages that are sent from the other
modules over the HS-CAN or MS-CAN to control the warning chime functions.
Warning Chime Characteristics
Each warning chime has unique characteristics to identify and differentiate each warning chime. The warning
chimes use volume, chime frequency, length of time the chime sounds and the number of chime tones to
identify which chime is sounding. The IPC prioritizes the chimes according to a preset hierarchy programmed
into the IPC software. When more than one chime request is received by the IPC , the most important chime
sounds. If a lower priority chime is currently sounding, the higher priority request takes over and replaces the
lower priority chime.
There are 3 different chimes as listed below:
• Repetitive
• Single tone
• Tick-tock
Compass 5165
The following table provides a summary of the chime characteristics.
Instrument Panel Cluster (IPC) Chime Characteristics
Chime
Chime Name Type Condition/Description
Air bag Repetitive Consists of five sets of chime sequences that make up a chime cycle. Each
chime sequence consists of 5 1-second chime tones followed by a 5 second
delay. The IPC sounds 5 chime sequences then turns off the air bag chime
for approximately 30 minutes. If the condition still exists, the air bag chime
repeats the chime cycle.
Belt-Minder® A/B Repetitive The chime sounds 6 chime tones/safety belt warning indicator flash
sequences for as long as the IPC receives the Belt-Minder® chime request.
Door ajar Repetitive The chime sounds repetitive tones for as long as the IPC receives a dooajar
chime command.
Headlamps on Repetitive The chime sounds repetitive tones for as long as the headlamps or the
parking lamps are on and the IPC receives the chime on command.
Hybrid Electric Repetitive The chime sounds 5 chime tones with the ignition in RUN, the transaxle in
Vehicle (HEV) PARK (P) and the driver door open or ajar.
engine off
Key-in-ignition Repetitive The chime sounds repetitive tones for as long as the key is in the ignition
with the ignition in OFF or ACC and the driver door is ajar.
Memory feedback Single This is a single tone chime that sounds when the IPC receives a chime
command as confirmation that the memory seat has been successfully set.
Message center Single This is a single tone chime that sounds once per ignition cycle whenever the
IPC receives a new message commanding on one of the message center
warnings.
Parking brake on Repetitive The chime sounds repetitive tones for as long as the parking brake is applied
and the IPC receives the chime on command.
Perimeter alarm Repetitive The chime sounds 3 sequences of chime tones. The first sequence sounds 12
tones when the driver door is opened using a key and the alarm is armed.
The second sequence sounds 9 chime tones followed by the third sequence
of 12 tones.
Safety belt Repetitive The chime sounds 6 times or as long as the safety belt is unbuckled and the
IPC receives the chime on command.
Service Roll Repetitive The chime sounds 3 tones for as long as the IPC receives a chime on
Stability Control command from the ABS module following an initial 8-second delay.
(RSC®)
Turn signal left on Repetitive Repetitive chime tone for as long as the RH or LH turn signal is on, the
vehicle has travelled 3.2 km (2.0 miles) and the IPC receives the chime on
command.
Turn signal Repetitive tick-tock tones for as long as the RH or LH turn signal command
Tick-tock
is received by the IPC .
Warning Chime Characteristics 5166

Air Bag Secondary Warning Chime
The air bag secondary warning chime warns that the air bag warning indicator light does not work correctly
and that a Supplemental Restraint System (SRS) fault condition exists. The IPC monitors the air bag warning
indicator status internally. When a fault is present in the air bag warning indicator and the IPC receives an air
bag warning indicator on request from the Restraints Control Module (RCM), the air bag secondary warning
chime sounds.
The air bag secondary warning chime sounds for 1 second on then 1 second off for 5 seconds (5 1-second
chime tones) then pauses for 5 seconds and repeats the chime on/off sequence for 5 minutes. The IPC then
turns off the air bag chime for approximately 30 minutes and repeats the cycle if the condition still exists.
The air bag secondary warning chime inputs are:
• Ignition state.
• Air bag warning indicator chime request communicated by the RCM to the IPC .
Belt-Minder®
The Belt-Minder® is configurable. To configure without using a scan tool, refer to Belt-Minder®
Deactivating/Activating in this section.
The Belt-Minder® feature supplements the current safety belt warning function and is enabled after the
current safety belt warning is complete. The Belt-Minder® reminds the driver that the driver or passenger
safety belt is unbuckled by intermittently and simultaneously sounding a chime and illuminating the safety
belt warning indicator in the IPC once the vehicle speed has exceeded 9.7 km/h (6 mph). The Belt-Minder®
remains active for 5 minutes from the time it is started.
While activated, the Belt-Minder® chime provides a series of 6 chime/safety belt warning indicator flash
sequences that when combined, make up a chime cycle. Each chime/safety belt warning indicator sequence
consists of a 1-second chime tone and safety belt warning indicator on/off state. The Belt-Minder® chime and
the safety belt warning indicator sound and flash for 6 seconds, then the chime stops and the safety belt
warning indicator remains on for 30 seconds. The IPC repeats the chime cycle for 5 minutes.
If the vehicle speed drops below 5 km/h (3 mph) once the Belt-Minder® chime has activated, the chime turns
off and the safety belt warning indicator remains on. When the vehicle speed exceeds (6 mph) again, the
Belt-Minder® chime resumes.
The IPC also provides a toll booth feature which allows the driver or passenger to unbuckle their safety belt
after the safety belts were initially buckled, providing 1 minute without warnings after the vehicle exceeds 9.7
km/h (6 mph) again with a safety belt unbuckled.
NOTE: Whenever the vehicle is operated using MyKey®, the RCM enables the Belt-Minder®.
When MyKey® is in use, the driver cannot configure the Belt-Minder® off. Once the Belt-Minder® is
activated, the Belt-Minder® continues to chime periodically (does not time out after 5 minutes) and the audio
system is muted until the driver and passenger safety belts are fastened. Refer to Section 419-01B for more
information on the MyKey® feature.
The Belt-Minder® warning chime inputs are the:
• Ignition state.
• Driver or passenger safety belt warning chime request communicated by the RCM to the IPC through
the HS-CAN .
• Safety belt warning indicator request communicated by the RCM to the IPC through the HS-CAN .
Air Bag Secondary Warning Chime 5167

Door Ajar Warning Chime
The door ajar warning chime warns that a door is ajar. The door ajar warning chime is a single chime with a 1
second duration. The door ajar chime sounds when the driver or passenger doors become ajar while the
ignition switch is in the RUN position.
The door ajar warning chime inputs are the:
• Ignition state.
• Door ajar, liftgate or liftgate glass message from the SJB .
Headlamps On Warning Chime
The headlamps on warning chime warns that the headlamps or parking lamps are on when the driver door is
ajar and the key is removed from the ignition lock cylinder. The headlamps on warning chime sounds if the
driver door is ajar and the headlamp switch is in the PARK or HEADLAMP position and the ignition is OFF
with the key out.
The headlamps on warning chime stops sounding when any one of the above conditions are removed.
The headlamps on warning chime inputs are:
• Ignition state.
• Key-in-ignition status to the SJB .
• Door ajar input from the driver door ajar switch to the SJB .
• Headlamp switch input to the SJB .
• Headlamps on chime request communicated by the SJB to the IPC through the MS-CAN .
Hybrid Electric Vehicle (HEV) Engine Off Chime
The HEV engine off chime sounds to remind the driver that the engine is not running and the vehicle is ready
to drive. The HEV warning chime sounds when the key is in RUN, the driver door is ajar and the transaxle is
in PARK (P).
The HEV warning chime inputs are:
• Ignition state.
• Door ajar status communicated from the SJB to the IPC through the MS-CAN .
• Transaxle park status communicated by the PCM to the IPC through the HS-CAN .
Key-In-Ignition Warning Chime
The key-in-ignition warning chime warns that the key is still in the ignition lock cylinder when the driver door
is ajar. The key-in-ignition warning chime sounds when the driver door is ajar, the key is in the ignition lock
cylinder and in the OFF or ACC position.
The key-in-ignition warning chime stops sounding when the driver door is closed, the key is removed from
the ignition lock cylinder, or if the ignition switch is turned to the ON position.
The key-in-ignition warning chime inputs are:
• Ignition state.
• Key-in-ignition switch position to the SJB .
Door Ajar Warning Chime 5168

• Key-in-ignition chime request communicated by the SJB to the IPC through the MS-CAN .
Message Center Warning Chime
The message center warning chime feature is used to draw the driver's attention to the message center display
to view a new warning message or message center warning indicator displayed. The IPC provides a single
one-second tone whenever a new warning message is displayed in the message center. If multiple warning
messages are present, the IPC sounds a chime for each of the warning messages that are present.
Memory Feedback Feature Chime
The purpose of the memory feedback feature chime is to inform the driver that their preferences have been
successfully programmed through the memory set procedure.
The memory feature chime inputs are:
• Ignition RUN/START status.

• Memory feedback chime request communicated by the Driver Seat Module (DSM) to the IPC over
the MS-CAN .
Parking Brake Warning Chime
The parking brake warning chime warns that the parking brake is engaged when the vehicle is in motion. The
parking brake warning chime sounds if the ignition is in RUN mode, the parking brake is engaged, and the
vehicle speed is greater than 5 km/h (3 mph).
The parking brake warning chime stops sounding if the parking brake is released, the ignition is not in the
RUN mode, if the vehicle speed is less than 5 km/h (3 mph), or after 90 seconds from the time the chime is
activated.
The parking brake warning chime inputs are:
• Ignition state.
• Parking brake switch status communicated by the SJB to the IPC through the MS-CAN .
• Vehicle speed data communicated by the PCM to the SJB through the MS-CAN .
• Parking brake warning chime request communicated by the SJB to the IPC .
Perimeter Alarm Chime
The perimeter alarm chime warning is used to alert the driver that the perimeter alarm is armed when the
driver door is unlocked with a key. The perimeter alarm warning chime is only functional when a key is used
to unlock the driver door. If the key fob or keypad (if equipped) is used to unlock the door, the perimeter
alarm is disarmed and the perimeter alarm warning chime does not sound. The perimeter alarm warning chime
sounds for 12 seconds when the driver door is opened and turns off when the perimeter alarm is disarmed
(either by using the key fob, keypad or turning the key to the ON position). After the 12 second chime
duration, the chime stops sounding and the perimeter alarm activates, sounding the horn and flashing the turn
signal lights.
The perimeter alarm chime inputs are:
• Ignition state.
• Passive Anti-Theft System (PATS) armed/disarmed status.
• Driver door ajar input to the SJB .
• Perimeter alarm chime request from the SJB to the IPC through the MS-CAN .
Key-In-Ignition Warning Chime 5169

Safety Belt Warning Chime
The safety belt warning chime warns that the safety belt is not fastened. The safety belt warning chime sounds
for 6 seconds when the driver safety belt is not fastened and the ignition switch is transitioned from the OFF
or ACC position to the ON or START position.
The safety belt warning chime stops sounding when the safety belt is fastened, when the ignition is switched
from the ON or START position to the OFF or ACC position, or when the chime has sounded for
approximately 6 seconds.
The safety belt warning chime inputs are:
• Ignition state.
• Driver or passenger safety belt warning chime request communicated by the RCM to the IPC through
the HS-CAN .
Service Roll Stability Control (RSC®) Warning Chime
The service RSC® warning chime warns that the ABS module has detected a fault condition in the RSC®
system. The SERVICE ADVANCETRAC message is also displayed along with the chime.
The service RSC® chime sounds for approximately 3 seconds following an initial delay of 8 seconds
following key ON. The RSC® chime stops sounding when the ignition switch is turned from the
RUN/START position to the OFF/LOCK or ACC position or when fault condition is repaired.
The service RSC® warning chime inputs are:
• Ignition state.
• Service RSC® chime request communicated by the ABS module to the IPC through the HS-CAN .
Turn Signal Left On Warning Chime
The turn signal left on warning chime warns that the turn signal has not been cancelled. The turn signal left on
warning chime sounds if the left or right turn signal is on and the vehicle has traveled more than 3.2 km (2.0
miles).
The turn signal left on warning chime stops sounding if the turn signal is turned off, or if the ignition is
switched to the OFF or ACC position.
The turn signal left on warning chime inputs are:
• Ignition state.
• Turn signal on data communicated by the SJB to the IPC through the MS-CAN .
• Odometer rolling count data communicated by the PCM to the IPC through the HS-CAN .
Turn/Hazard On Tone
Since the turn/hazard flasher is an electronic funcion of the SJB , the on/off sound that used to be present with
standard bi-metal flashers is no longer present. To provide an audible sound and indicate that the RH/LH turn
or hazard indicators are on, the IPC provides a tick-tock tone along with the visual turn signal indicators.
The turn/hazard on tone inputs are:
• Left turn indicator signal from the SJB to the IPC through the MS-CAN .
• Right turn indicator signal from the SJB to the IPC through the MS-CAN .
Safety Belt Warning Chime 5170

• Accessory drive belt • Smart Junction Box (SJB)

• Brake fluid level fuse(s):
• Compass module (integral to the auto-dimming interior ♦ 14 (7.5A) ( FDIM )
mirror) (compass display)
• Engine oil level ♦ 26 (10A)
• Engine coolant level ♦ 29 (5A)
• Front Display Interface Module (FDIM) ♦ 41 (15A) (compass
• Fuel tank module)
• Fuel evaporative system • Wiring, terminals or
• Tire pressure connectors
• Tire size • Instrument Panel Cluster (IPC)



418-00 .
Turn/Hazard On Tone 5171

8. Clear the continuous DTCs and carry out the self-test diagnostics for the IPC , SJB , PCM, ABS
module and Restraints Control Module (RCM).
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - Instrument Panel Cluster
(IPC) , GO to Symptom Chart - Information And Message Center , or GO to Symptom Chart -
Warning Chimes .
Instrument Panel Cluster (IPC) Dealer Test Mode - Non-Hybrid
To enter the IPC self-diagnostic mode, begin with the ignition key in the OFF position. Press and hold the
message center SETUP and RESET buttons. Turn the key to the RUN position and hold the buttons until the
display indicates ENGINEERING TEST MODE at the top of the right hand display (usually within 3 to 5
seconds) then release both buttons. Press the RESET button once to advance through each stage of the
self-test. To exit the IPC self-test mode, turn the ignition to the OFF position.
NOTE: If the message center detects a non-resettable fault condition that it is reporting out on such as door
ajar, the dealer test mode session cannot be entered until the fault condition has been corrected and the
message removed. If the dealer test mode session is interrupted by the fault condition display (such as door
ajar), the session can be resumed by pressing the RESET button.
NOTE: Some of the displays listed in the table below use xxx's to represent a numeric or alpha-numeric
value. The value may display the same amount of characters represented by the xxx's or there may be
more/less depending on the type of display. For example: VEHICLE SPEED xxxx.x MPH may display
VEHICLE SPEED 25 MPH. Note that there were 4 x's in the display description but only 2 digits in the actual
display.
Fusion
Second Line
First Line Display Display Description
ENGINEERING TEST MODE Initial entry display into the self-test mode.
GAUGE TEST Carries out the gauge sweep of all gauges, then displays the
present gauge values. Also carries out the checksum test on
Read-Only Memory (ROM).
All VF segments - Carries out the prove-out of all dot matrix pixels in all characters.
illuminated
TELLTALE TEST Illuminates all the microprocessor-controlled lamps and LEDs.
PART NUMBER xxxx-xx Return to normal operation of all microprocessor-controlled
lamps/LEDs and displays the alpha-numeric prefix and suffix of
the IPC part number.
ROM LEVEL $xxxx Displays the hexadecimal ROM level and type.
$xxxx Displays the
hexadecimal
EEPROM level
and type.
SW RELEASE xx/xx/xx

Displays the software release date in mm/dd/yy format stored in

Non-Volatile Memory (NVM).
ROM CHECKSUM $xxxxxxxx Shows the ROM checksum data.
$xxxxxxxx PASS = passed.
$xxxxxxxx FAIL = failed.
$--- CALC = calculating the checksum.

MANUFACTURE DATE $xxxx Displays hexadecimal coding of the final manufacturing test date.
MANUF CONFIG BYTE 1 $xx Displays hexadecimal coding of vehicle options NVM for line 1 of
As-Built data for ABS/traction control/interactive vehicle
dynamics, oil life threshold, Tire Pressure Monitoring System
(TPMS) and Belt-Minder®.
B&A CONFIG BYTE 1-6 $xx Displays hexadecimal coding of vehicle options NVM for lines 1
through 6 of As-Built data.
CONTINUOUS DTC $xxxxxx Displays DTCs in 16-bit hexadecimal format. DTCs displayed are
those detected in continuous operation not during self-test.
If no DTCs are present, the DTC: None is displayed.

VEHICLE SPEED xxx.x MPH Displays the English speed value being inputs in tenths of mph to
the Instrument Panel Cluster (IPC), the speedometer indicates the
present filtered speed.
If the High Speed Controller Area Network (HS-CAN) message is

missing, the second line displays ---.- MPH.
If the HS-CAN message is invalid, the second line displays INV

MPH.
If the vehicle speed input is an unknown value, UNKNOWN MPH

is displayed.
VEHICLE SPEED xxx.x km/h Displays the metric speed value being inputs in tenths of km/h to
the IPC , the speedometer indicates the present filtered speed.
If the HS-CAN message is missing, the second line displays ---.-

km/h.
If the HS-CAN message is invalid, the second line displays

INVALID km/h.
If the vehicle speed input is an unknown value, UNKNOWN km/h

is displayed.
TACHOMETER xxxx RPM Displays the tachometer value being input in rpm to the IPC . The
tachometer indicates the present filtered rpm.
If the HS-CAN message is missing, the second line displays ---.-

RPM.
If the HS-CAN message is invalid, the second line displays INV

RPM.

If the engine speed input is an unknown value, UNKNOWN RPM

is displayed.
FUEL 1 LEVEL xxx INSTANT Displays the present primary (fuel pump module) unfiltered fuel
level.
000-009 = short circuit.
010-254 = normal range.
255 = open.
INV = invalid input.

FUEL 2 LEVEL xxx INSTANT Displays the present secondary (fuel level sender) unfiltered fuel
level.
000-009 = short circuit.
255 = open.

FUEL 1 LEVEL % STATUS xxx Display present filtered primary (fuel pump module) input for fuel
level percent status.
0255= open or short circuit detected.

FUEL 2 LEVEL % STATUS xxx Display present filtered secondary (fuel level sender) input for fuel
level percent status.
0255= open or short circuit detected.

INSTANT DTE xxx MILES NOTE: This display may differ from the DTE displayed in the
INFO menu of the message center due to the use of the unfiltered
DTE calculation.
Displays the calculated (unfiltered) Distance To Empty (DTE) in

miles.
--- = invalid input.

RAFE DTE xx.x MPG Displays the running fuel economy in decimal.
If the fuel raw average fuel economy message is missing, the

second line displays ---.- MPG.
If the fuel raw average fuel economy message is invalid, the

second line displays INVALID MPG.

FUEL 1 ON/OF/SZ xxx xxx Displays the key on, key off, and zero speed samples for the fuel
pump module.
If the input is invalid, the message center displays--- ---.

FUEL 2 ON/OF/SZ xxx xxx xxx Displays the key on, key off, and zero speed samples for the
secondary fuel level input (fuel level sender).
If the input is invalid, the message center displays --- --- ---.
F1 #S ON/OFF/SZ xxx xxx xxx Displays the number of valid samples used for key on, key off, and
zero speed samples for the primary fuel level input (fuel pump
module).
F2 #S ON/OFF/SZ xxx xxx xxx Displays the number of valid samples used for key on, key off, and
zero speed samples for the secondary fuel level input (fuel level
sender).
COOLANT TEMP xxx C Displays the last temperature gauge input value from the PCM
over the HS-CAN in degrees C, temperature gauge indicates the
present filtered temperature.
If the temperature message is missing, the second line displays ---

C.
If the temperature message is invalid, the second line displays INV

C.
ODOMETER xxx COUNTS Displays the unfiltered odometer rolling count input received over
the HS-CAN from the PCM, in decimal.
If the odometer rolling count data is missing, the second line

displays --- COUNTS.
If the odometer rolling count data is invalid, the second line

displays INV counts.
COMPASS TX=$xx CLUSTER Display data received from the compass module and transmitted
RX=$xx by the IPC to the compass module.
If there is a communication concern with the compass module, the

message center displays $--.
If the compass is configured off, the message center displays,

COMPASS CONFIGURED OFF.
BATTERY xxx.x VOLTS Displays the present battery reading in volts at the IPC input pin.
DIMMING CMD xxx Displays the dimming command message in percentage from the
SJB over the MS-CAN .
If the dimming command message is missing, the second line

displays ---.
If the dimming command message is invalid, the second line

displays INV.
DIMVAL $xx LITVAL $xx Displays the dimming and lighting values from the SJB over the
MS-CAN .
0-21 = normal range with 0 indicating off.

22-253 = out of range.
254 = unknown value.
255 = invalid value.
If the dimming and lighting value messages are missing, the line
displays ---.
If the dimming and lighting value messages are invalid, the line
displays INV.
If the dimming value is OK and the lighting value is unknown,

DIMVAL xxx LITVAL UN is displayed.
If the dimming value is invalid and the lighting value is unknown,

DIMVAL INV LITVAL UN is displayed.
MC SWITCH xxx A/D CNTS Displays current message center switch input analog/digital counts
in decimal (0-255).
LOW WASHER SWITCH xxxx Display the hardwired low washer fluid status received from the
washer fluid level switch.
The message center displays HIGH or LOW depending upon the

state of the low washer fluid switch.
OIL PRESSURE SWITCH xxx Display the hardwired engine oil pressure status received from the
engine oil pressure switch.
The message center displays HIGH or LOW depending upon the

state of the engine oil pressure switch.
LAST CHIME SOUNDED Displays the last chime that sounded.
xxxxxx
STBELT = safety belt, AIRBAG = air bag secondary, KEYIN =
key in ignition, TRNSIG = turn signal reminder, DOOR = door
ajar, HDLMPS = headlamps on, MSGCTR = message center
warning tone, PRKBRK = park brake warning, BLTMDR =
Belt-Minder® and MEMORY = memory feedback.
If the input is unknown, the message center displays ---.

DIGITAL PORT 0-9, $xx Displays 8 bit hexadecimal value of the digital port readings.
A, B, C, E or F
ANALOG PORT 0-9 $xx Displays 10 bit hexadecimal value of the analog port readings.
GAUGE TEST Repeats the test display cycle.
Instrument Panel Cluster (IPC) Dealer Test Mode - Hybrid
To enter the IPC self-diagnostic mode, begin with the ignition key in the OFF position. Press and hold the
message center SETUP and RESET buttons. Turn the key to the RUN position and hold the buttons until the
display indicates ENGINEERING TEST MODE at the top of the right hand display (usually within 3 to 5
seconds) then release both buttons. Press the RESET button once to advance through each stage of the
self-test. To exit the IPC self-test mode, turn the ignition to the OFF position.

The dealer test mode displays multiple items in a viewing window on the RH side of the IPC . Each button
press advances the viewing window to the next set of items.
NOTE: If the message center detects a non-resettable fault condition that it is reting out on such as door ajar,
the dealer test mode session cannot be entered until the fault condition has been corrected and the message
removed. If the dealer test mode session is interrupted by the fault condition display (such as door ajar), the
session can be resumed by pressing the RESET button.
NOTE: Some of the displays listed in the table below use xxx's to represent a numeric or alpha-numeric
value. The value may display the same amount of characters represented by the xxx's or there may be
more/less depending on the type of display. For example: DTC HIST CURR xxxxxx x x may display DTC
HIST CURR C10000 X. Note that there were 8 x's in the display description but only 7 digits in the actual
display.
Button Press Viewing Window Display Description

1 ENGINEERING TEST Initial entry display into the self-test mode.
MODE
2 ANALOG GAUGE Carries out the gauge sweep of the speedometer, then
displays the present gauge value. Also carries out the
TEST checksum test on Read-Only Memory (ROM).
3 TELLTALE Illuminates all the microprocessor-controlled lamps
and LEDs.
TEST
4 PartNo: xxxx-xx Displays the IPC part number, manufacturing date,
Electrically Erasable Programmable Read-Only
VIP sw: xxxx-xx Memory (EEPROM) and the end of line configuration.
GIP sw: xx.xx.xxx
eeprom sw: xx.xx
Man Date: xxxxxx
B&A ConfigByte: xx xx xx xx
xx xx
5 Inst Fuel xx/xxxx Displays the fuel level inputs used to indicate fuel
level.
Fuel Level % xx.xx
State % #Sample
OFF x x
ON x x
SZ x x
6 Vehicle Speed Displays the current vehicle speed and engine rpm
inputs received over the HS-CAN .
x.x km/h

x.x mph
Tachometer
x rpm
7 DTE xxx km Displays the instantaneous fuel economy inputs
received from the PCM over the HS-CAN .
xxx mi
RAFE xx.xx kml
xx.xx MPG
x-xx l/100 km
8 Odo cnts: x Displays the odometer values received from the PCM
over the HS-CAN and the battery voltage input.
Trip A: xxx.x km
Trip A: xxx.x mi
Trip B: xxx.x km
Trip B: xxx.x mi
Battery: x.x v
9 Dim Step: xx/xx Displays the illumination dimming input and current
dimming settings.
Dim Gauge: xxx
Dim Pointer: xxx
Dim Display: xxxx

10 MC A2D SW1: xx Displays the current message center switch button
state, oil pressure switch state, coolant temperature,
MC A2D SW1: xx compass and the last chime sounded.
Oil Press SW: xx
Coolant Temp: xx
Compass: xx x
Last Chime:
xxxxxxxx
11 DTC HIST CURR Displays any stored DTC information as a historical
code, current code or both.
xxxxxx x x
12 ENGINEERING TEST Initial entry display into the self-test mode.
MODE

DTC Charts
NOTE: This module utilizes a 5-character DTC followed by a 2-character failure-type code. The failure-type
code provides information about specific fault conditions such as opens, or shorts to ground. Continuous
memory DTCs have an additional 2-character DTC status code suffix to assist in determining DTC history.
Instrument Panel Cluster (IPC) DTC Chart

B109E:42 Remote Keyless Entry: REFER to Section 501-14 .
General Memory Failure
B109E:51 Remote Keyless Entry: Not REFER to Section 501-14 .
Programmed
B109E:86 Remote Keyless Entry: Signal REFER to Section 501-14 .
Invalid
B10D5:13 PATS Antenna: Circuit Open REFER to Section 419-01B (non-hybrid) or Section 419-01C
(hybrid).
B10D7:05 PATS Key: System REFER to Section 419-01B (non-hybrid) or Section 419-01C
Programming Failure (hybrid).
B10D7:51 PATS Key: Not Programmed REFER to Section 419-01B (non-hybrid) or Section 419-01C
(hybrid).
B10D7:87 PATS Key: Missing Message REFER to Section 419-01B (non-hybrid) or Section 419-01C
(hybrid).
B10D7:8F PATS Key: Erratic REFER to Section 419-01B (non-hybrid) or Section 419-01C
(hybrid).
B10D8:00 PATS Key Less Than REFER to Section 419-01B (non-hybrid) or Section 419-01C
Minimum Programmed: No (hybrid).
Sub-Type Information
B10D9:87 PATS Transponder: Missing REFER to Section 419-01B (non-hybrid) or Section 419-01C
Message (hybrid).
B10DA:51 PATS PCM Identifier: Not REFER to Section 419-01B (non-hybrid) or Section 419-01C
Programmed (hybrid).
B10DA:61 PATS PCM Identifier: Signal REFER to Section 419-01B (non-hybrid) or Section 419-01C
Calculation Failure (hybrid).
B10DA:86 PATS PCM Identifier: Signal REFER to Section 419-01B (non-hybrid) or Section 419-01C
Invalid (hybrid).
B1A82:09 External Trip Switch: CLEAR the DTCs. REPEAT the self-test.
Component Failure
If DTC B1A82:09 returns on Fusion, INSTALL a new cruise
control switch. REFER to Section 419-03 . CLEAR the DTCs.
If DTC B1A82:09 returns on MKZ, INSTALL a new Front

Controls Interface Module (FCIM). REFER to Section 415-00 .

If DTC B1A82:09 returns on hybrid vehicles, INSTALL a new

LH steering wheel switch. REFER to Section 419-03 . CLEAR
B1A82:11 External Trip Switch: Circuit GO to Pinpoint Test AU .
Short to Ground
B1A82:13 External Trip Switch: Circuit GO to Pinpoint Test AU .
Open
C0089:11 TCS Disable Switch: Circuit REFER to Section 206-09 .
Short To Ground
P0460:11 Fuel Level Sensor A Circuit: With a single sender L-shaped fuel tank, GO to Pinpoint Test B .
With a dual sender saddle-type fuel tank, GO to Pinpoint Test C .
P0460:13 Fuel Level Sensor A Circuit: With a single sender L-shaped fuel tank, GO to Pinpoint Test B .
Circuit Open
With a dual sender saddle-type fuel tank, GO to Pinpoint Test C .
P1243:06 Second Fuel Pump Fault or GO to Pinpoint Test C .
Ground Fault: Algorithm
Based Failure
P1346:11 Fuel Level Sensor B Circuit: GO to Pinpoint Test C .
P1346:13 Fuel Level Sensor B Circuit: GO to Pinpoint Test C .
Circuit Open
P1534:01 Restraint Deployment INSTALL a new Instrument Panel Cluster (IPC). REFER to
Indicator Circuit: General Instrument Panel Cluster (IPC) in this section.
Electrical Failure
P1706:00 High Vehicle Speed Observed GO to Pinpoint Test AJ .
in Park: No Sub-Type
Information
P1706:62 High Vehicle Speed Observed GO to Pinpoint Test AJ .
in Park: Signal Compare
Failure
U0002:88 High Speed CAN REFER to Section 418-00 .
Communication Bus
Performance: Bus Off
U0011:88 Medium Speed CAN REFER to Section 418-00 .
Communication Bus
Performance: Bus Off
U0100:00 Lost Communication With GO to Pinpoint Test BF .
ECM /PCM "A": No
U0101:00 Lost Communication With GO to Pinpoint Test BG .
TCM : No Sub-Type
Information
U0102:00 Lost Communication With GO to Pinpoint Test BH .
Transfer Case Control
Module: No Sub-Type
Information
U010F:00 Lost Communication With Air GO to Pinpoint Test BI .
Conditioning Control Module:
No Sub-Type Information

U0111:00 Lost Communication With GO to Pinpoint Test BJ .

Battery Energy Control
Module "A": No Sub-Type
Information
U0121:00 Lost Communication With GO to Pinpoint Test BK .
Anti-Lock Brake System
(ABS) Control Module: No
U0131:00 Lost Communication With GO to Pinpoint Test BL .
Power Steering Control
Module: No Sub-Type
Information
U0140:00 Lost Communication With GO to Pinpoint Test BM .
Body Control Module: No
U0151:00 Lost Communication With GO to Pinpoint Test BN .
Restraints Control Module:
U0154:00 Lost Communication With GO to Pinpoint Test BO .
Restraints Occupant
Classification Sensor ( OCS ):
U0159:00 Lost Communication With GO to Pinpoint Test BP .
Parking Assist Control
Module "A": No Sub-Type
Information
U0161:00 Lost Communication With GO to Pinpoint Test CA .
Compass Module: No
U0163:00 Lost Communication With GO to Pinpoint Test BQ .
Navigation Control Module:
U0164:00 Lost Communication With GO to Pinpoint Test BR .
HVAC Control Module: No
U0184:00 Lost Communication With GO to Pinpoint Test BS .
Radio: No Sub-Type
Information
U0208:00 Lost Communication With GO to Pinpoint Test BT .
"Seat Control Module A": No
U0232:00 Lost Communication With GO to Pinpoint Test BU .
Side Obstacle Detection
Control Module Left: No
U0233:00 Lost Communication With GO to Pinpoint Test BV .
Control Module Right: No
U0298:00 Lost Communication With DC GO to Pinpoint Test BW .
to DC Control Module "A":

U0401:68 Invalid Data Received from DTC U0401:68 is set when the IPC receives invalid network data
ECM /PCM A: Event from the PCM. RETRIEVE and REPAIR all non-network DTCs
Information in the other modules on the network. REFER to Section 419-10
for a list of all DTCs.
TCM : Event Information from the Transmission Control Module (TCM). RETRIEVE and
REPAIR all non-network DTCs in the TCM and other modules
on the network. REFER to Section 419-10 for a list of all DTCs.
U040A:68 Invalid Data Received from DTC U040A:68 is set when the IPC receives invalid network data
Air Conditioning Control from the HVAC module. RETRIEVE and REPAIR all
Module: Event Information non-network DTCs in the HVAC and other modules on the
network. REFER to Section 419-10 for a list of all DTCs.
Battery Energy Control from the Battery Pack Sensor Module (BPSM). RETRIEVE and
Module A: Event Information REPAIR all non-network DTCs in the BCM-HVTB and other
modules on the network. REFER to Section 419-10 for a list of all
DTCs.
Anti-Lock Brake System from the ABS module. RETRIEVE and REPAIR all non-network
(ABS) Control Module: Event DTCs in the ABS module and other modules on the network.
Information REFER to Section 419-10 for a list of all DTCs.
U0422:68 Invalid Data Received from NOTE: If new modules were installed prior to the DTC being set,
Body Control Module: Event the module configuration may be incorrectly set during the
Information Programmable Module Installation (PMI) or the PMI may not
have been carried out.
DTC U0422:68 is set when the IPC receives invalid network data
from the Smart Junction Box (SJB) for backlighting, brake fluid
level or Tire Pressure Monitoring System (TPMS). RETRIEVE
and REPAIR all non-network DTCs in the SJB and other modules
Tire Pressure Monitor from the SJB for TPMS . RETRIEVE and REPAIR all
Module: Event Information non-network DTCs in the SJB and other modules on the network.
REFER to Section 419-10 for a list of all DTCs.
Restraints Control Module: from the Restraints Control Module (RCM). RETRIEVE and
Event Information REPAIR all non-network DTCs in the RCM and other modules
U0462:00 Invalid Data Received from GO to Pinpoint Test CA .
Compass Module: No Sub
Type Information
U0462:68 Invalid Data Received from REFER to Section 419-10 for a list of all DTCs
Compass Module: Event
Information
U0533:68 Invalid Data Received from REFER to Section 419-04 for a list of all DTCs.
Control Module-Left: Event
Information
U0534:68 REFER to Section 419-04 for a list of all DTCs.

Invalid Data Received from

Control Module-Right: Event
Information
DC to DC Converter Control from the DC to DC Converter Control Module (DC/DC).
Module "A": Event RETRIEVE and REPAIR all non-network DTCs in the DC/DC
Information and other modules on the network. REFER to Section 419-10 for
a list of all DTCs.
U2100:00 Initial Configuration Not CARRY OUT the PMI procedure for the IPC . REFER to Section
Complete: No Sub-Type 418-01 .
Information
U3000:41 Control Module: General CLEAR the DTCs. REPEAT the self-test.
Checksum Failure
If DTC U3000:41 returns, INSTALL a new IPC . REFER to
Instrument Panel Cluster (IPC) in this section. TEST the system
U3000:42 Control Module: General CLEAR the DTCs. REPEAT the self-test.
Memory Failure
U3000:43 Control Module: Special CLEAR the DTCs. REPEAT the self-test.
Memory Failure
U3000:44 Control Module: Data CLEAR the DTCs. REPEAT the self-test.
Memory Failure
U3000:45 Control Module: Program CLEAR the DTCs. REPEAT the self-test.
Memory Failure
U3000:46 Control Module: CLEAR the DTCs. REPEAT the self-test.
Calibration/Parameter
Memory Failure If DTC U3000:46 returns, INSTALL a new IPC . REFER to
U3003:16 Battery Voltage: Circuit GO to Pinpoint Test BX .
U3003:17 Battery Voltage: Circuit GO to Pinpoint Test BY .
U300A:62 Ignition Switch: Signal GO to Pinpoint Test BZ .
Compare Failure
U300A:64 Ignition Switch: Signal GO to Pinpoint Test BZ .
Plausibility Failure


B2479 Brake Park Switch Circuit Short GO to Pinpoint Test T .
to Ground
B1352 Ignition Key-In Circuit Failure If the chime sounds with the door ajar and no key in the
ignition, GO to Pinpoint Test AY .
If the key-in-ignition chime is inoperative, GO to Pinpoint

Test AZ .
C1125 Brake Fluid Level Sensor Input GO to Pinpoint Test T .
Circuit Failure
All other - REFER to the Diagnostic Trouble Code (DTC) Chart in
DTCs Section 419-10 .
PCM DTC Chart

P0460 Fuel Level Sensor A Circuit REFER to the Powertrain Control/Emissions Diagnosis (PC/ED)
manual first.
If sent here from the PC/ED manual, GO to Pinpoint Test B for

single sender L-shaped fuel tank or GO to Pinpoint Test C for dual
sender saddle-type fuel tank.
Range/Performance manual first.

Low manual first.

High manual first.

P2065 Fuel Level Sensor B Circuit REFER to the Powertrain Control/Emissions Diagnosis (PC/ED)
manual first.
If sent here from the PC/ED manual, GO to Pinpoint Test C .

Range/Performance manual first.


Low manual first.

High manual first.

All other - REFER to the Powertrain Control/Emissions Diagnosis (PC/ED)
DTCs manual.
Symptom Charts
Symptom Chart - Instrument Panel Cluster (IPC)
Symptom Chart - Information And Message Center
Symptom Chart - Warning Chimes
Pinpoint Tests
Pinpoint Test A: The Instrument Panel Cluster (IPC) Is Inoperative
Refer to Wiring Diagrams Cell 60 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Instrument Cluster for
Normal Operation
With the ignition in the START or RUN mode, the Instrument Panel Cluster (IPC) receives voltage from the
Smart Junction Box (SJB) fuse 29 (5A). With the ignition in the OFF mode, the IPC receives its keep-alive
voltage from the SJB fuse 26 (10A). The IPC grounding is through a single ground. The IPC sets DTC
U300A:62 in continuous memory and on-demand if the RUN/START input is open or if the SJB fuse 29 (5A)
has failed.
• Fuse(s)
• IPC
PINPOINT TEST A: THE IPC IS INOPERATIVE
NOTICE: Failure to use the correct probe adapter(s) may damage the connector.

A1 RETRIEVE THE RECORDED DTCs FROM

THE CONTINUOUS IPC SELF-TEST
Yes
• Check for recorded IPC DTCs from the VERIFY SJB fuse 29 (5A) is OK. If OK, GO to
continuous self-test. Pinpoint Test BZ . If not OK, REFER to the
• Is DTC U300A:62 recorded? Wiring Diagrams Manual to identify the possible
No
GO to A2 .
A2 CHECK THE IPC VOLTAGE SUPPLY
Yes
• Disconnect: IPC C220 .
• For the non-hybrid, measure the voltage No
between the IPC C220-21, circuit SBP26 VERIFY SJB fuse 26 (10A) is OK. If OK,
(YE/RD), harness side and ground. REPAIR the circuit for an open. If not OK,
REFER to the Wiring Diagrams Manual to
identify the possible causes of the circuit short.
• For the hybrid, measure the voltage between

the IPC C220-19, circuit SBP26 (YE/RD),

A3 CHECK THE IPC GROUND CIRCUIT FOR
AN OPEN
Yes
• For the non-hybrid, measure the voltage
between the IPC C220-21, circuit SBP26 No
(YE/RD), harness side and the IPC C220-5, REPAIR circuit GD116 (BK/VT) for an open.
circuit GD116 (BK/VT), harness side. TEST the system for normal operation.
PINPOINT TEST A: THE IPC IS INOPERATIVE 5186

• For the hybrid, measure the voltage between

the IPC C220-19, circuit SBP26 (YE/RD),
harness side and the IPC C220-9, circuit
GD116 (BK/VT), harness side.

A4 CHECK FOR CORRECT IPC OPERATION
Yes
• Disconnect the IPC connector. INSTALL a new IPC . REFER to Instrument
• Check for: Panel Cluster (IPC) in this section. TEST the
♦ corrosion system for normal operation.
♦ damaged pins
• Connect the IPC connector and make sure it The system is operating correctly at this time.
seats correctly. The concern may have been caused by a loose or
• Operate the system and determine if the corroded connector.
Pinpoint Test B: Incorrect Fuel Gauge Indication - Single Sender L-Shaped Fuel Tank
Normal Operation
The fuel pump module is hardwired to the Instrument Panel Cluster (IPC) between the signal circuit and the
signal return circuit, which is grounded internally within the IPC . The fuel level sender (float and card) is a
variable resistor attached to the fuel pump module that ranges from 180 ohms ± 4 ohms at empty (E) and 10
ohms ± 2 ohms at full (F). The IPC provides a reference voltage to the fuel pump module on the signal circuit.
Ae fuel level changes, a float actuates a variable resistor on the fuel level sender (float and card), raising or
lowering the fuel level signal voltage depending on the resistance of the fuel level sender. The IPC monitors
the changes in voltage and commands the fuel gauge with a corresponding movement of the pointer.
On flex-fuel vehicles, basic fuel level indication is the same as gasoline vehicles, except that the flex-fuel
vehicles require a DC-AC interface (internal to the IPC ), used to prevent chemical reactions created by the
interaction of A/C current with the fuel.

The IPC uses 4 different operating modes to calculate the fuel level:
• Anti-slosh (default mode)

• Ignition OFF fueling
• Ignition ON fueling
• Recovery
After a fuel fill up, the time for the fuel gauge to move from empty (E) to full (F) ranges from 2 seconds to 55
minutes depending on which operating mode the fuel gauge is in.
Anti-Slosh Mode
The default fuel gauge mode is called the anti-slosh mode. To prevent fuel gauge changes from fuel slosh
(gauge instability due to changes in fuel sensor readings caused by fuel moving around in the tank), the fuel
gauge takes approximately 55 minutes to go from empty (E) to full (F).
Key OFF Fueling Mode
The ignition OFF fueling mode (2 seconds to read empty [E] to full [F]) requires 3 conditions be met:
• The ignition must be in the OFF mode when refueling the vehicle.
• At least 15% of the vehicle's fuel capacity must be added to the fuel tank.
• The IPC must receive a valid ignition ON fuel sensor reading within one second of the ignition being
put into the RUN mode. The key ON sample readings are considered valid if the fuel sensor reading is
between 10 ohms ± 2 ohms and 180 ohms ± 4 ohms.
If these conditions are not met, the fuel gauge stays in the anti-slosh mode, which results in a slow to read full
(F) event.
Key ON Fueling Mode
The ignition ON fueling mode (approximately 60 seconds to read empty [E] to full [F]) requires the following
conditions be met:
• Engine speed greater than 0 rpm.

• The transaxle is in PARK (P) or NEUTRAL (N).
• The ignition is in the RUN mode.
In ignition ON fueling mode, a 30-second timer activates after the transaxle is put into the PARK (P) or
NEUTRAL (N) position. When the 30-second time has elapsed and at least 15% of the vehicle's fuel capacity
has been added, the fuel gauge response time is 60 seconds to read from empty (E) to full (F). When the
transaxle is shifted out of PARK (P) or NEUTRAL (N), the fuel gauge strategy reverts to the anti-slosh mode.
The ignition ON fueling mode prevents slow to read full events from happening if the customer refuels the
vehicle with the ignition in the RUN mode.
Recovery Mode
Recovery mode is incorporated into the IPC strategy to recover from a missing fuel level input after a
refueling event. Missing fuel level inputs result from intermittent opens in the fuel sensor or its circuits.
Recovery mode (empty [E] to full [F] approximately 20 minutes) is initiatewhen the following 2 conditions
are met:
• The IPC is in the anti-slosh (default) mode.

• The actual fuel level in the tank is greater than what is being displayed by the fuel gauge.
Anti-Slosh Mode 5188

Instrument Panel Cluster (IPC) DTCs

A continuous and on-demand DTC that sets in the IPC if the IPC detects that the
• P0460:11 - Fuel fuel pump module is out of range on the input circuit with a short to ground for 33
Level Sensor A seconds. The IPC defaults the fuel gauge to empty (E), once the IPC detects a fault
Circuit: Circuit and sets DTC P0460:11.
Short to Ground
A continuous and on-demand DTC that sets in the IPC he IPC detects that the fuel
• P0460:13 - Fuel pump module is out of range on the input circuit with an open or short to voltage
Level Sensor A on the input or return circuits for 33 seconds. The IPC defaults the fuel gauge to
Circuit: Circuit empty (E), once the IPC detects a fault and sets DTC P0460:13.
Open
PCM DTCs

Sets when the PCM determines the value of the fuel level input signal is
• P0460 - Fuel Level stuck, that the fuel level input signal does not change or does not correspond
Sensor A Circuit with the calculated fuel usage.
Sets when the PCM determines the fuel level input signal repeatedly moves
• P0461 - Fuel Level in and out of range, exceeding the minimum or maximum allowable
Sensor A Circuit calibrated parameters for a specified fuel fill percentage in the fuel tank.
Range/Performance
Sets in the PCM when the PCM detects a short to ground on the fuel pump
• P0462 - Fuel Level module signal circuit based on the messaged input received from the IPC .
Sensor A Circuit Low
Sets in the PCM when the PCM detects an open or a short to voltage on the
• P0463 - Fuel Level fuel pump module signal circuit based on the messaged input received from
Sensor A Circuit High the IPC .

• Fuel pump module
• Fuel level sender (float and card)
• Fuel tank
• IPC
PINPOINT TEST B: INCORRECT FUEL GAUGE INDICATION - SINGLE SENDER L-SHAPED FUEL TANK
Recovery Mode 5189

NOTE: Following any fuel gauge repairs, remove fuse 26 (10A) for one minute then reinstall to reset the fuel
gauge timers.

B1 RETRIEVE THE RECORDED DTCs FROM THE
IPC SELF-TEST
Yes
• Check for recorded DTCs from the IPC self-test. For DTC P0460:13, GO to B3 .
• Are any DTCs rded?
For DTC P0460:11, GO to B7 .
For all other DTCs, REFER to DTC Charts

in this section.
No
GO to B2 .
B2 CARRY OUT THE IPC FUEL GAUGE ACTIVE
COMMAND USING THE SCAN TOOL
Yes
tool: IPC DataLogger . No
• NOTE: Make sure to set the scan tool to empty or GO to B13 .
0% before beginning this test.
• Select the IPC fuel gauge (FUELLEVEL) active
command. Command the fuel gauge from 0% to
25%, 50%, 75% and 100% while observing the fuel
gauge.
• Does the fuel gauge begin at E (empty), move to
approximately 1/8-1/4, just under 1/2, 3/4 and F
(full)?
B3 CHECK THE FUEL PUMP MODULE FOR AN
OPEN
Yes
• Ignition OFF. REMOVE the jumper wire. GO to B12 .
• Disconnect: Fuel Pump Module C433 .
• Connect a fused jumper wire between the fuel pump No
module C433-1, circuit RMC32 (GN/BU), harness REMOVE the jumper wire. GO to B4 .
side and the fuel pump module C433-2, circuit
VMC11 (YE/VT), harness side.
• Ignition ON.
• Wait one minute.
PINPOINT TEST B: INCORRECT FUEL GAUGE INDICATION - SINGLE SENDER L-SHAPED5190

FUEL TANK

tool: IPC Self-Test .
• NOTE: DTC P0460:13 may also be present when
carrying out this step and should be ignored at this
time.
• Repeat the IPC self-test.
• Retrieve the IPC continuous DTCs.
• Is DTC P0460:11 retrieved?
B4 CHECK THE FUEL LEVEL SIGNAL AND
RETURN CIRCUITS FOR A SHORT TO VOLTAGE
Yes
• Ignition OFF. REPAIR the circuit in question. CLEAR
• Disconnect: IPC C220 . the DTCs. REPEAT the self-test.
• Ignition ON.
• For non-hybrid, measure the voltage between the No
IPC C220-15, circuit VMC11 (YE/VT), harness GO to B5 .
side and ground; and between the IPC C220-2,
circuit RMC32 (GN/BU), harness side and ground.
• For hybrid, measure the voltage between the IPC

C220-25, circuit VMC11 (YE/VT), harness side and
ground; and between the IPC C220-12, circuit
RMC32 (GN/BU), harness side and ground.

B5 CHECK THE FUEL LEVEL SIGNAL CIRCUIT
FOR AN OPEN
Yes
• For non-hybrid, measure the resistance between the
IPC C220-15, circuit VMC11 (YE/VT), harness No
side and the fuel pump module assembly C433-2, REPAIR the circuit. CLEAR the DTCs.
circuit VMC11 (YE/VT), harness side. REPEAT the self-test.

FUEL TANK
• For hybrid, measure the resistance between the IPC

the fuel pump module assembly C433-2, circuit
VMC11 (YE/VT), harness side.

B6 CHECK THE FUEL LEVEL RETURN CIRCUIT
FOR AN OPEN
Yes
• For non-hybrid, measure the resistance between the GO to B13 .
IPC C220-2, circuit RMC32 (GN/BU), harness side
and the fuel pump module assembly C433-1, circuit No
RMC32 (GN/BU), harness side. REPAIR the circuit. CLEAR the DTCs.

C220-12, circuit RMC32 (GN/BU), harness side
and the fuel pump module assembly C433-1, circuit
RMC32 (GN/BU), harness side.

B7 CHECK THE FUEL PUMP MODULE FOR A
SHORT TO GROUND

FUEL TANK
• Disconnect: Fuel Pump Module C433 . Yes

• Enter the following diagnostic mode on the scan No
tool: IPC Self-Test . GO to B8 .
time.
B8 CHECK THE FUEL LEVEL SIGNAL AND
RETURN CIRCUITS FOR A SHORT TOGETHER
Yes
• On non-hybrid, measure the resistance between the No
IPC C220-15, circuit VMC11 (YE/VT), harness REPAIR the circuits. CLEAR the DTCs.
side and the IPC C220-2, circuit RMC32 (GN/BU), REPEAT the self-test.
harness side.
• On hybrid, measure the resistance between the IPC

the IPC C220-12, circuit RMC32 (GN/BU), harness
side.

B9 CHECK THE FUEL LEVEL SIGNAL CIRCUIT
Yes
• For non-hybrid, measure the resistance between the GO to B13 .
IPC C220-15, circuit VMC11 (YE/VT), harness
side and ground. No
REPAIR the circuit. CLEAR the DTCs.

FUEL TANK

ground.

B10 CHECK THE FUEL LEVEL INPUT TO THE
IPC
Yes
NOTE: Since the IPC may be in anti-slosh fuel DISCONNECT the instrument gauge
indication mode, the self-test and tester values may system tester. GO to B11 .
not match the fuel gauge readings. The actual gauge
indication should be disregarded during this test No
step. DISCONNECT the instrument gauge
system tester. GO to B13 .
• Ignition OFF.
• Disconnect: Fuel Pump Module Assembly C433 .
• Connect one lead of the instrument gauge system
tester to the fuel pump module assembly C433-2,
circuit VMC11 (YE/VT), harness side and the other
lead to the fuel pump module assembly C433-1,
circuit RMC32 (GN/BU), harness side.
• Ignition ON.
tool: IPC PIDs .
• NOTE: It is extremely important to confirm the
gauge tester settings with an ohmmeter to make sure
that the gauge tester is in the correct position.
Failure to follow this check may result in inaccurate
test results.

FUEL TANK
• Monitor the IPC fuel level (FLI) PID, with the

gauge tester set at 180 ohms, 90 ohms, 55 ohms, 30
ohms and 10 ohms.
• Does the PID begin at approximately 0%, move
to 25%, 50%, 75% then 100%?
B11 CHECK THE FUEL TANK
Yes
• Check the fuel tank for any damage or deformation. GO to B12 .
• Is the fuel tank OK?
No
VERIFY the fuel level sensor and fuel
pump module are OK. INSTALL a new
fuel tank. REFER to Section 310-01A
(non-hybrid) or Section 310-01B (hybrid).
B12 CHECK THE FUEL LEVEL SENDER (FLOAT
AND CARD)
Yes
NOTE: The fuel level sender (float and card) INSTALL a new fuel pump module.
resistance measures between 180 ohms ± 4 ohms at REFER to Section 310-01A (non-hybrid)
the lower stop position and 10 ohms ± 2 ohms at the or Section 310-01B (hybrid). CLEAR the
upper stop position. DTCs. REPEAT the self-test.
• Remove the fuel pump module. Refer to Section No

310-01A (non-hybrid) or Section 310-01B (hybrid). INSTALL a new fuel level sender (float
• NOTE: Disconnect the fuel level sender (float and and card). REFER to Section 310-01A
card) input wire from the fuel pump module for this (non-hybrid) or Section 310-01B (hybrid).
measurement. CLEAR the DTCs. REPEAT the self-test.
• Measure the resistance between the fuel level
sender (float and card) input wire and the fuel level
sender (float and card) ground while slowly moving
the float arm between the lower and upper stop
position.
• Does the resistance slowly decrease from

approximately 180 ohms at the lower stop to 10
ohms at the upper stop?
B13 CHECK FOR CORRECT IPC OPERATION
Yes
• Disconnect the IPC connector. INSTALL a new IPC . REFER to
• Check for: Instrument Panel Cluster (IPC) in this
♦ corrosion section. TEST the system for normal
♦ damaged pins operation.
♦ pushed-out pins

FUEL TANK
• Connect the IPC connector and make sure it seats No

correctly. The system is operating correctly at this
• Operate the system and verify the concern is still time. The concern may have been caused
present. by a loose or corroded connector. CLEAR
• Is the concern still present? the DTCs. REPEAT the self-test.
Pinpoint Test C: Incorrect Fuel Gauge Indication - Dual Sender Saddle-Type Fuel Tank
Normal Operation
The fuel tank is a saddle tank design with 2 variable resistance senders, driven by floats, that provide
resistances related to fuel level in each side of the fuel tank to the Instrument Panel Cluster (IPC). The fuel
level is determined using variable resistance fuel sender units, with an approximate resistance range between
180 ohms ± 4 ohms at empty (E) and 10 ohms ± 2 ohms at full (F). The IPC provides a reference voltage to
the fuel pump module (LH side) and fuel level sensor (RH side) through individual signal circuits and
receives a return through the signal return circuits from both the fuel pump module and fuel level sensor. As
the fuel level changes, a float actuates a variable resistor on the fuel pump module and fuel level sensor,
raising or lowering the fuel level signal voltage depending on the resistance of the fuel level sender (flt and
card). The IPC monitors the changes in voltage from both senders and commands the fuel gauge with a
corresponding movement of the pointer. If the IPC detects the fuel level sensor circuitry is open, the fuel
gauge defaults to the fuel pump module value only and the fuel gauge indicates empty (E). If the IPC detects
the fuel pump module circuitry is open, the fuel gauge defaults to the empty position.
On flex-fuel vehicles, basic fuel level indication is the same as gasoline vehicles, except that the flex-fuel
vehicles require a DC-AC interface (internal to the IPC ), used to prevent chemical reactions created by the
interaction of A/C current with the fuel.
The IPC uses 4 different operating modes to calculate the fuel level:
• Anti-slosh (default mode)

• Ignition OFF fueling
• Ignition ON fueling
• Recovery
After a fuel fill up, the time for the fuel gauge to move from empty (E) to full (F) ranges from 2 seconds to 55
minutes depending on which operating mode the fuel gauge is in.
Anti-Slosh Mode
The default fuel gauge mode is called the anti-slosh mode. To prevent fuel gauge changes from fuel slosh
(gauge instability due to changes in fuel sensor readings caused by fuel moving around in the tank), the fuel
gauge takes approximately 55 minutes to go from empty (E) to full (F).
Key OFF Fueling Mode
The ignition OFF fueling mode (2 seconds to read empty [E] to full [F]) requires 3 conditions be met:
• The ignition must be in the OFF mode when refueling the vehicle.
• The IPC must receive a valid ignition ON fuel sensor reading within one second of the ignition being
put into the RUN mode. The key ON sample readings are considered valid if the fuel sensor reading is

between 10 ohms ± 2 ohms and 180 ohms ± 4 ohms.
If these conditions are not met, the fuel gauge stays in the anti-slosh mode, which results in a slow to read full
(F) event.
Key ON Fueling Mode
The ignition ON fueling mode (approximately 60 seconds to read empty [E] to full [F]) requires the following
conditions be met:
• Engine speed greater than 0 rpm.

• The transaxle is in PARK (P) or NEUTRAL (N).
• The ignition is in the RUN mode.
In ignition ON fueling mode, a 30-second timer activates after the transaxle is put into the PARK (P) or
NEUTRAL (N) position. When the 30-second time has elapsed and at least 15% of the vehicle's fuel capacity
has been added, the fuel gauge response time is 60 seconds to read from empty (E) to full (F). When the
transaxle is shifted out of PARK (P) or NEUTRAL (N), the fuel gauge strategy reverts to the anti-slosh mode.
The ignition ON fueling mode prevents slow to read full events from happening if the customer refuels the
vehicle with the ignition in the RUN mode.
Recovery Mode
Recovery mode is incorporated into the IPC strategy to recover from a missing fuel level input after a
refueling event. Missing fuel level inputs result from intermittent opens in the fuel sensor or its circuits.
Recovery mode (empty [E] to full [F] approximately 20 minutes) is initiated when the following 2 conditions
are met:
• The IPC is in the anti-slosh (default) mode.

• The actual fuel level in the tank is greater than what is being displayed by the fuel gauge.
Instrument Panel Cluster (IPC) DTCs

A continuous and on-demand DTC that sets in the
• P0460:11 - Fuel Level Sensor A Circuit: Circuit IPC if the IPC detects that the fuel pump module
Short to Ground is out of range on the signal circuit with a short to
ground for 33 seconds. The IPC defaults the fuel
gauge to empty (E), once the IPC detects a fault d
sets DTC P0460:11.
• P0460:13 - Fuel Level Sensor A Circuit: Circuit IPC if the IPC detects that the fuel pump module
Open is out of range on the signal circuit with an open
or short to voltage for 33 seconds. The IPC
defaults the fuel gauge to empty (E), once the IPC
detects a fault and sets DTC P0460:13.
• P1346:11 - Fuel Level Sensor B Circuit: Circuit IPC if the IPC detects that the fuel level sensor is
Short to Ground out of range on the signal circuit with a short to
ground for 33 seconds. The IPC defaults the fuel
Key OFF Fueling Mode 5197

gauge to empty (E), once the IPC detects a fault

and sets DTC P1346:11.
• P1346:13 - Fuel Level Sensor B Circuit: Circuit IPC if the IPC detects that the fuel level sensor is
Open out of range on the signal circuit with an open or
short to voltage for 33 seconds. The IPC defaults
the fuel gauge to empty (E), once the IPC detects
a fault and sets DTC P1346:13.
NOTE: Normal operation of the fuel delivery system Sets when the IPC detects a large discrepancy in
allows the fuel sensor side of the fuel tank (RH side) to the amount of fuel (based on input from both fuel
have less fuel than the side with the fuel pump module sensors) between both sides of the fuel tank.
(LH side).
P1243:06 - Second Fuel Pump Fault or Ground Fault:

Algorithm Based Failure
PCM DTCs

Sets when the PCM determines the value of the fuel level input signal is
• P0460 - Fuel Level stuck, that the fuel level input signal does not change or does not
Sensor A Circuit correspond with the calculated fuel usage.
Sets when the PCM determines the fuel level input signal repeatedly moves
• P0461 - Fuel Level in and out of range, exceeding the minimum or maximum allowable
Sensor A Circuit calibrated parameters for a specified fuel fill percentage in the fuel tank.
Range/Performance
Sets in the PCM when the PCM detects a short to ground on the fuel pump
• P0462 - Fuel Level module signal circuit based on the messaged input received from the IPC .
Sensor A Circuit Low
Sets in the PCM when the PCM detects an open or a short to voltage on the
• P0463 - Fuel Level fuel pump module signal circuit based on the messaged input received
Sensor A Circuit High from the IPC .
Sets when the PCM determines the value of the fuel level sensor input
• P2065 - Fuel Level signal is stuck, that the fuel level input signal does not change or does not
Sensor B Circuit correspond with the calculated fuel usage.
Sets when the PCM determines the fuel level sensor input signal repeatedly
• P2066 - Fuel Level moves in and out of range, exceeding the minimum or maximum allowable
Sensor B Circuit calibrated parameters for a specified fuel fill percentage in the fuel tank.
Range/Performance
/TD>
Sets in the PCM when the PCM detects a short to ground on the fuel level
• P2067 - Fuel Level sensor signal circuit based on the messaged input received from the IPC .
Sensor B Circuit Low
Sets in the PCM when the PCM detects an open or short to voltage on the
• P2068 - Fuel Level fuel level sensor signal circuit on the messaged input received from the IPC
Sensor B Circuit High .
Recovery Mode 5198

• Fuel tank transfer tube
• Fuel pump module (LH side)
• Fuel level sensor (RH side)
• Fuel level sender (float and card)
• Fuel lines
• Fuel tank
• IPC
PINPOINT TEST C: INCORRECT FUEL GAUGE INDICATION - DUAL SENDER SADDLE-TYPE FUEL TANK
NOTE: Following any fuel gauge repairs, remove fuse 26 (10A) for one minun reinstall to reset the fuel
gauge timers.

C1 RETRIEVE THE RECORDED DTCs FROM THE
IPC SELF-TEST
Yes
• Ignition OFF. For DTC P0460:11 or P1346:11, GO to
• Check for recorded DTCs from the IPC self-test. C3 .
• Are any DTCs recorded?
For DTC P0460:13, GO to C7 .
No
GO to C2 .
C2 CARRY OUT THE IPC FUEL GAUGE ACTIVE
Yes
• Ignition ON. GO to C15 .
IPC DataLogger . No
• NOTE: Make sure to set the scan tool to empty or 0% GO to C21 .
before beginning this test.
• Select the IPC fuel gauge (FUELLEVEL) active
command. Command the fuel gauge from 0% to 25%,
50%, 75% and 100% while observing the fuel gauge.
• Does the fuel gauge begin at E (empty), move to
approximately 1/8-1/4, just under 1/2, 3/4 and F
(full)?
C3 CHECK THE FUEL SENSOR FOR A SHORT TO
GROUND
Yes
• Disconnect: Fuel Pump Module C433 (DTC P0460:11) INSTALL a new fuel pump module
or Fuel Level Sensor C3270 (DTC P1346:11) . (DTC P0460:11) or fuel level sensor
PINPOINT TEST C: INCORRECT FUEL GAUGE INDICATION - DUAL SENDER SADDLE-TYPE

5199
FUEL TAN
• Ignition ON. (DTC P1346:11). REFER to Section

• Wait one minute. 310-01A . CLEAR the DTCs. REPEAT
• Enter the following diagnostic mode on the scan tool: the self-test.
IPC Self-Test .
• NOTE: DTC P0460:11 or P1346:11 may also be No
present. GO to C4 .
• Repeat the IPC on-demand self-test.
• Is DTC P0460:13 or P1346:13 retrieved?
C4 CHECK THE FUEL LEVEL SIGNAL CIRCUITS
Yes
• Ignition OFF. For DTC P0460:11, GO to C5 .
• Measure the resistance between the IPC C220-15 (DTC For DTC P1346:11, GO to C6 .
P0460:11), circuit VMC11 (YE/VT), harness side and
ground; or between the IPC C220-14 (DTC P1346:11), No
circuit VMC23 (GN/OG), harness side and ground. REPAIR the circuit in question.
self-test.

C5 CHECK THE FUEL PUMP MODULE SIGNAL AND
Yes
• Measure the resistance between the IPC C220-15, GO to C21 .
circuit VMC11 (YE/VT), harness side and between the
IPC C220-2, circuit RMC32 (GN/BU), harness side. No
REPAIR the circuit in question.
self-test.

C6 CHECK THE FUEL LEVEL SENSOR SIGNAL AND
Yes
circuit VMC23 (GN/OG), harness side and the IPC
C220-1, circuit RMC33 (WH/VT), harness side. No
self-test.

5200
FUEL TAN

C7 CHECK THE FUEL PUMP MODULE FOR AN
OPEN
Yes
• Ignition OFF. REMOVE the jumper wire. GO to C20 .
• Disconnect: Fuel Pump Module C433 .
• Connect a fused jumper wire between the fuel pump No
module C433-1, circuit RMC32 (GN/BU), harness side REMOVE the jumper wire. GO to C8 .
and the fuel pump module C433-2, circuit VMC11
• Ignition ON.
IPC Self-Test .
time.
C8 CHECK THE FUEL LEVEL SIGNAL AND RETURN
Yes
• Ignition OFF. REPAIR the circuit in question.
• Disconnect: IPC C220 . CLEAR the DTCs. REPEAT the
• Ignition ON. self-test.
• Measure the voltage between the IPC C220-15, circuit
VMC11 (YE/VT), harness side and ground; and No
between the IPC C220-2, circuit RMC32 (GN/BU), GO to C9 .

5201
FUEL TAN

C9 CHECK THE FUEL LEVEL SIGNAL CIRCUIT FOR
AN OPEN
Yes
• Measure the resistance between the IPC C220-15,
circuit VMC11 (YE/VT), harness side and the fuel No
pump module assembly C433-2, circuit VMC11 REPAIR the circuit. CLEAR the DTCs.
(YE/VT), harness side. REPEAT the self-test.

C10 CHECK THE FUEL LEVEL RETURN CIRCUIT
FOR AN OPEN
Yes
• Measure the resistance between the IPC C220-2, circuit GO to C21 .
RMC32 (GN/BU), harness side and the fuel pump
module assembly C433-1, circuit RMC32 (GN/BU), No
harness side. REPAIR the circuit. CLEAR the DTCs.

C11 CHECK THE FUEL LEVEL SENSOR CIRCUITRY
FOR AN OPEN
Yes
• Connect a fused jumper wire between the fuel level REMOVE the jumper wire. INSTALL a
sensor C3270-2, circuit VMC23 (GN/OG), harness side new fuel level sensor. REFER to
and the fuel level sensor C3270-1, circuit RMC33 Section 310-01A . CLEAR the DTCs.
(WH/VT), harness side. REPEAT the self-test.
No

5202
FUEL TAN
REMOVE the jumper wire. GO to C12 .
• Ignition ON.
IPC Self-Test .
time.
C12 CHECK THE FUEL LEVEL SENSOR CIRCUITRY
FOR A SHORT TO VOLTAGE
Yes
• Disconnect: IPC C220 . REPAIR the circuit in question.
• Ignition ON. CLEAR the DTCs. REPEAT the
• Measure the voltage between the IPC C220-14, circuit self-test.
VMC23 (GN/OG), harness side and ground; and
between the IPC C220-1, circuit RMC33 (WH/VT), No
harness side and ground. GO to C13 .

C13 CHECK THE FUEL LEVEL SENSOR SIGNAL
CIRCUIT FOR AN OPEN
Yes
circuit VMC23 (GN/OG), harness side and the fuel
level sensor C3270-2, circuit VMC23 (GN/OG), No
harness side. REPAIR the circuit. CLEAR the DTCs.

5203
FUEL TAN

C14 CHECK THE FUEL LEVEL SENSOR RETURN
CIRCUIT FOR AN OPEN
Yes
• Measure the resistance between the IPC C220-1, circuit GO to C21 .
RMC33 (WH/VT), harness side and the fuel level
sensor C3270-1, circuit RMC33 (WH/VT), harness No
side. REPAIR the circuit. CLEAR the DTCs.

C15 CHECK THE FUEL LEVEL INPUT TO THE IPC
Yes
indication mode, the self-test and tester values may not system tester. GO to C16 .
match the fuel gauge readings. The actual gauge
indication should be disregarded during this test step. No
DISCONNECT the instrument gauge
• Ignition OFF. system tester. GO to C21 .
• Disconnect: Fuel Pump Module Assembly C433 .
• Connect one lead of the instrument gauge system tester
to the fuel pump module assembly C433-2, circuit
VMC11 (YE/VT), harness side and the other lead to
RMC32 (GN/BU), harness side.
• Ignition ON.
IPC PIDs .
• NOTE: It is extremely important to confirm the gauge
tester settings with an ohmmeter to make sure that the

5204
FUEL TAN
gauge tester is in the correct position. Failure to follow

this check may result in inaccurate test results.
• Monitor the IPC fuel level (FUELLVL1) PID, with the
ohms and 10 ohms.
• Does the PID begin at approximately 3%, move to
70%, 127%, 185% then 251%?
C16 CHECK THE FUEL LEVEL INPUT TO THE IPC
Yes
indication mode, the self-test and tester values may not system tester. GO to C17 .
match the fuel gauge readings. The actual gauge
indication should be disregarded during this test step. No
DISCONNECT the instrument gauge
• Ignition OFF. system tester. GO to C21 .
• Disconnect: Fuel Level Sensor C3270 .
• Connect one lead of the instrument gauge system tester
to the fuel pump module assembly C3270-2, circuit
VMC23 (GN/OG), harness side and the other lead to
RMC33 (WH/VT), harness side.
• Ignition ON.
IPC PIDs .
• NOTE: It is extremely important to confirm the gauge
tester settings with an ohmmeter to make sure that the
gauge tester is in the correct position. Failure to follow
this check may result in inaccurate test results.
• Monitor the IPC fuel level (FUELLVL2) PID, with the
ohms and 10 ohms.
• Does the PID begin at approximately 3%, move to
70%, 127%, 185% then 251%?
C17 INSPECT THE FUEL TANK
Yes
• Visually inspect the fuel tank for any damage or GO to C18 .
deformation.
• Is the fuel tank OK? No
INSTALL a new fuel tank. REFER to
Section 310-01A . CLEAR the DTCs.
REPEAT the self test.
C18 INSPECT THE FUEL TANK TRANSFER TUBE
CONNECTIONS

5205
FUEL TAN
• Remove the fuel pump module and the fuel level Yes
sensor. Refer to Section 310-01A . GO to C19 .
• Inspect the fuel tank transfer tube, connections, the fuel
pump module and the fuel level sensor for any damage No
or deformation. INSTALL a new fuel tank transfer tube,
• Are the fuel tank transfer tube, connections, the fuel fuel pump module or fuel level sensor
pump module and the fuel level sensor OK? as necessary. REFER to Section
310-01A . CLEAR the DTCs. REPEAT
the self test.
C19 CHECK THE FUEL PUMP MODULE AND THE
FUEL LEVEL SENSOR FOR CORRECT OPERATION
Yes
NOTE: The resistance varies from 180 ± 4 ohms when For DTC P1243:06, INSTALL a new
empty (E) to 10 ± 2 ohms when full (F). fuel tank transfer tube or fuel level
sensor as required. REFER to Section
• For the fuel pump module, measure the resistance 310-01A . CLEAR the DTCs. REPEAT
between the fuel pump module C433 pin 1, component the self test.
side and the fuel pump module C433 pin 2, component
side while slowly moving the float arm from the For no DTCs, the concern may have
bottom to the top of travel. been caused by an intermittent input to
the IPC most likely caused by corrosion
on one of the fuel level senders (float
and card).
No
For the fuel pump module, GO to C20 .
For the fuel level sensor, INSTALL a

new fuel level sensor. REFER to
Section 310-01A . CLEAR the DTCs.
• For the fuel level sensor, measure the resistance
between the fuel level sensor C3270 pin 1, component
side and the fuel level sensor C3270 pin 2, component
side while slowly moving the float arm from the
bottom to the top of travel.
• Does the resistance start at approximately 180 ohms

with the float at the bottom of travel and slowly
increase to approximately 10 ohms at the top of
travel?
C20 CHECK THE FUEL LEVEL SENDER (FLOAT
AND CARD)

5206
FUEL TAN
NOTE: The fuel level sender (float and card) Yes

resistance measures between 180 ohms ± 4 ohms at the INSTALL a new fuel pump module or
lower stop position and 10 ohms ± 2 ohms at the upper fuel level sensor as necessary. REFER
stop position. to Section 310-01A . CLEAR the DTCs.
• Remove the fuel pump module or fuel level sensor.
Refer to Section 310-01A . No
• NOTE: Disconnect the fuel level sender (float and INSTALL a new fuel level sender (float
card) input wire from the fuel pump module for this and card). REFER to Section 310-01A .
measurement. CLEAR the DTCs. REPEAT the
• Measure the resistance between the fuel level sender self-test.
(float and card) input wire and the fuel level sender
(float and card) ground while slowly moving the float
arm between the lower and upper stop position.
• Does the resistance slowly decrease from

approximately 180 ohms at the lower stop to 10
ohms at the upper stop?
C21 CHECK FOR CORRECT IPC OPERATION
Yes
♦ pushed-out pins
• Operate the system and verify the concern is still time. The concern may have been
present. caused by a loose or corroded
• Is the concern still present? connector. CLEAR the DTCs. REPEAT
the self-test.
Pinpoint Test D: The Temperature Gauge Is Inoperative
Normal Operation
The PCM uses the Cylinder Head Temperature (CHT) sensor to measure the engine temperature. The
Instrument Panel Cluster (IPC) receives the engine temperature data from the PCM over the High Speed
Controller Area Network (HS-CAN) communication bus. The IPC monitors the engine temperature data
received from the PCM and commands the temperature gauge indication with a corresponding movement of
the pointer.
The non-hybrid and hybrid temperature gauges appear differently but essentially function the same. The
non-hybrid gauge is an analog gauge with a needle that points to a specified area of the gauge depending on

the data received from the PCM. The hybrid gauge is a digital display that appears as a thermometer. The fill
color of the thermometer is blue when the temperature is between the cold and normal ranges. When the
temperature indicates an overheating condition, the fill color turns to red.
If the engine temperature data is missing for 5 seconds or less or if the IPC receives invalid engine
temperature data for 5 seconds or less, the IPC defaults the temperature gauge to the last setting, based upon
the last known good temperature status message. If the IPC does not receive the engine temperature status
message for more than 5 seconds, the IPC sets DTC U0100:00 in continuous memory and defaults the
temperature gauge to cold (C). If the engine temperature data is deemed invalid by the IPC for 5 seconds or
more, the IPC sets DTC U0401:68 and defaults the temperature gauge to cold (C).
NOTE: If DTC U0100:00 is set in the IPC , other observable symptoms may be an inoperative tachometer,
speedometer or odometer.
• PCM
• IPC
PINPOINT TEST D: THE TEMPERATURE GAUGE IS INOPERATIVE

D1 RETRIEVE THE RECORDED DTCs FROM
THE PCM KOEO SELF-TEST
Yes
• Check for recorded PCM DTCs from the Key DIAGNOSE all PCM DTCs first. REFER to the
ON Engine OFF (KOEO) self-test. Powertrain Control/Emissions Diagnosis
• Are any DTCs recorded? (PC/ED) manual.
No
GO to D2 .
D2 CARRY OUT THE TEMPERATURE
GAUGE ACTIVE COMMAND USING THE
SCAN TOOL
Yes
scan tool: IPC DataLogger . No
• NOTE: The coolant temperature should range INSTALL a new IPC . REFER to Instrument
between 0-59°C (32-138°F) with the gauge in Panel Cluster (IPC) in this section. TEST the
the cold (C) range, between 60-120°C system for normal operation.
(140-248°F) with the gauge in the normal or
mid-range and above 123°C (253°F) with uge
in the hot (H) range.
• Select the IPC temperature gauge
(ENGCOOLNT) active command. Command
the temperature gauge according to the
following table:
PINPOINT TEST D: THE TEMPERATURE GAUGE IS INOPERATIVE 5208

Temperature
Command Gauge Position
0% Full cold (C)
50% Just under the center of the
gauge (mid-range)
(non-hybrid)
Just above the center of the

gauge (mid-range) (hybrid)
100% Full hot (H)
• Does the temperature gauge start at cold

(C), move to the mid-range and end at full
hot (H)?
D3 RETRIEVE THE RECORDED DTCs FROM
THE IPC SELF-TEST
Yes
• Check for recorded DTCs from the IPC For DTC U0100:00, GO to Pinpoint Test BF .
self-test.
• Are any DTCs recorded? For DTC U0401:68, RETRIEVE and REPAIR
all non-network DTCs in the PCM and other
modules on the network. REFER to the
Powertrain Control/Emissions Diagnosis
(PC/ED) manual and Section 419-10 for a list of
all DTCs.
For all other DTCs, REFER to DTC Charts in

this section.
No
INSTALL a new PCM. REFER to Refer to the
appropriate section in Group 303 for the
procedure.. TEST the system for normal
operation.
Pinpoint Test E: Incorrect Temperature Gauge Indication
Normal Operation
The PCM uses the Cylinder Head Temperature (CHT) sensor to measure the engine temperature. The
Instrument Panel Cluster (IPC) receives the engine temperature data from the PCM over the High Speed
Controller Area Network (HS-CAN) communication bus. The IPC monitors the engine temperature data
received from the PCM and commands the temperature gauge indication with a corresponding movement of
the pointer.
The non-hybrid and hybrid temperature gauges appear differently but essentially function the same. The
non-hybrid gauge is an analog gauge with a needle that points to a specified area of the gauge depending on
the data received from the PCM. The hybrid gauge is a digital display that appears as a thermometer. The fill
color of the thermometer is blue when the temperature is between the cold and normal ranges. When the
temperature indicates an overheating condition, the fill color turns to red.

If the engine temperature data is missing for 5 seconds or less or if the IPC receives invalid engine
temperature data for 5 seconds or less, the IPC defaults the temperature gauge to the last setting, based upon
the last known good temperature status message. If the IPC does not receive the engine temperature status
message for more than 5 seconds, the IPC sets DTC U0100:00 in continuous memory and defaults the
temperature gauge to cold (C). If the engine temperature data is deemed invalid by the IPC for 5 seconds or
more, the IPC sets DTC U0401:68 and defaults the temperature gauge to cold (C).
speedometer or odometer.
• PCM concern
• IPC
PINPOINT TEST E: INCORRECT TEMPERATURE GAUGE INDICATION

E1 CHECK FOR CORRECT OPERATION OF THE
COOLING SYSTEM
Yes
• Verify that the engine cooling system and thermostat are GO to E2 .
functioning correctly.
• Does the engine cooling system and thermostat No
operate correctly? REFER to Section 303-03A
(non-hybrid) or Section 303-03B
(hybrid).
E2 RETRIEVE THE RECORDED DTCs FROM THE
PCM KOEO SELF-TEST
Yes
• Check for recorded PCM DTCs from the Key ON DIAGNOSE all PCM DTCs first.
Engine OFF (KOEO) self-test. REFER to Powertrain
• Are any DTCs recorded? Control/Emissions Diagnosis (PC/ED)
manual.
No
GO to E3 .
E3 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Yes
• Check for recorded DTCs from the IPC self-test. For DTC U0100:00, GO to Pinpoint
• Are any DTCs recorded? Test BF .
For DTC U0401:68, RETRIEVE and

REPAIR all non-network DTCs in the
PCM and other modules on the
network. REFER to the Powertrain
manual and Section 419-10 for a list of
all DTCs.
PINPOINT TEST E: INCORRECT TEMPERATURE GAUGE INDICATION 5210

For all other DTCs, REFER to DTC

Charts in this section.
No
GO to E4 .
E4 CARRY OUT THE TEMPERATURE GAUGE
ACTIVE COMMAND USING THE SCAN TOOL
Yes
IPC DataLogger . No
• NOTE: The coolant temperature should range between INSTALL a new IPC . REFER to
0-59°C (32-138°F) with the gauge in the cold (C) range, Instrument Panel Cluster (IPC) in this
between 60-120°C (140-248°F) with the gauge in the section. TEST the system for normal
normal or mid-range and above 123°C (253°F) with the operation.
gauge in the hot (H) range.
• Select the IPC temperature gauge (ENGCOOLNT)
active command. Command the temperature gauge
according to the following table:
Temperature Command Gauge Position

0% Full cold (C)
20% Beginning of the normal
band
50% Just under the center of the
gauge (mid-range)
(non-hybrid)
Just above the center of the

gauge (mid-range) (hybrid)
90% Beginning of the hot (H)
band
100% Full hot (H)
• Does the temperature gauge indicate the correct

temperature according to the above specifications?
E5 CHECK THE COOLANT TEMPERATURE INPUT
USING THE DEALER TEST MODE
Yes
• Ignition ON. The temperature gauge is operating
• Enter the IPC dealer test mode. correctly at this time.
• NOTE: The display below uses xxx's to represent a
numeric or alpha-numeric value. The value may display No
the same amount of characters represented by the xxx's INSTALL a new IPC . REFER to
or there may be more/less depending on the type of Instrument Panel Cluster (IPC) in this
display and that the minus symbol in parenthesis only section. TEST the system for normal
appears if the temperature is below 0°C. For example: operation.
COOLANT TEMP xxx C (non-hybrid) or Coolant
Temp: xx (hybrid) may display COOLANT TEMP 20 C
PINPOINT TEST E: INCORRECT TEMPERATURE GAUGE INDICATION 5211

(non-hybrid).
• Scroll through the displays to COOLANT TEMP xxx C
(non-hybrid) or Coolant Temp: xx (hybrid).
• Start the engine and run the engine through a variety of
engine temperatures.
• NOTE: The coolant temperature should range between
0-59°C (32-138°F) with the gauge in the cold (C) range,
between 60-120°C (140-248°F) with the gauge in the
normal or mid-range and above 123°C (253°F) with the
gauge in the hot (H) range.
• Monitor the engine temperature input to the IPC and the
coolant temperature gauge indication.
• Does the engine input agree with the position of the
temperature gauge indication?
Pinpoint Test F: The Speedometer Is Inoperative
Normal Operation
The Instrument Panel Cluster (IPC) receives the Vehicle Speed Sensor (VSS) signal from the PCM
(non-hybrid) or from the Transmission Control Module (TCM) (hybrid) over the High Speed Controller Area
Network (HS-CAN) communication bus. The PCM or TCM receives the VSS input from the Output Shaft
Speed (OSS). The IPC monitors the VSS input from the PCM or TCM and commands the speedometer with a
corresponding movement of the pointer.
If the vehicle speed data is missing for 5 seconds or less or if the IPC receives invalid vehicle speed data for 5
seconds or less, the IPC defaults the speedometer to the last setting, based upon the last known good vehicle
speed message. If the IPC does not receive the vehicle speed data for more than 5 seconds, the IPC sets DTC
U0100:00 (non-hybrid) or U0101:00 (hybrid) in continuous memory and defaults the speedometer to 0 km/h
(0 mph). If the vehicle speed data received is deemed invalid by the IPC for 5 seconds or more, the IPC sets
DTC U0401:68 (non-hybrid) or U0402:68 and defaults the speedometer to 0 km/h (0 mph).
temperature gauge or odometer.
• PCM (non-hybrid)
• TCM (hybrid)
• IPC
PINPOINT TEST F: THE SPEEDOMETER IS INOPERATIVE

F1 RETRIEVE THE RECORDED DTCs
FROM THE PCM AND TCM KOEO
SELF-TEST
Yes
• Check for recorded PCM and TCM DIAGNOSE all PCM and TCM DTCs first. REFER to
DTCs from the Key ON Engine OFF Powertrain Control/Emissions Diagnosis (PC/ED) manual.
(KOEO) self-test.

• Are any DTCs recorded? No

GO to F2 .
F2 CARRY OUT THE SPEEDOMETER
ACTIVE COMMAND USING THE
SCAN TOOL
Yes
• Enter the following diagnostic mode
on the scan tool: IPC DataLogger . No
• Select the IPC speedometer INSTALL a new IPC . REFER to Instrument Panel
(SPDOMETER) active command. Cluster (IPC) in this section. TEST the system for normal
Command the speedometer operation.
according to the following table
while monitoring the speedometer.
Speedometer Gauge
Command Position
0% 0 km/h (0 mph)
50% 97 km/h (60
mph)
100% 193 km/h (120
mph)
• Does the speed begin at 0 km/h (0

mph) move to 97 km/h (60 mph)
then 193 km/h (120 mph) and
return to 0 km/h (0 mph)?
F3 RETRIEVE THE RECORDED DTCs
FROM THE IPC SELF-TEST
Yes
• Check for recorded DTCs from the For DTC U0100:00 (non-hybrid), GO to Pinpoint Test BF
IPC self-test. .
For DTC U0101:00 (hybrid), GO to Pinpoint Test BG .
For DTC U0401:68 (non-hybrid) or U0402:68 (hybrid),

RETRIEVE and REPAIR all non-network DTCs in the
PCM and other modules on the network. REFER to the
Powertrain Control/Emissions Diagnosis (PC/ED) manual
and Section 419-10 for a list of all DTCs.
For all other DTCs, REFER to DTC Charts in this section.
No
For non-hybrid vehicles, INSTALL a new PCM. REFER
to Refer to the appropriate section in Group 303 for the
procedure.. TEST the system for normal operation.
For hybrid vehicles, INSTALL a new transaxle ( TCM ).
PINPOINT TEST F: THE SPEEDOMETER IS INOPERATIVE 5213

REFER to Section 307-01C . TEST the system for normal

operation.
Pinpoint Test G: Incorrect Speedometer Indication
Normal Operation
The Instrument Panel Cluster (IPC) receives the Vehicle Speed Sensor (VSS) signal from the PCM
(non-hybrid) or from the Transmission Control Module (TCM) (hybrid) over the High Speed Controller Area
Network (HS-CAN) communication bus. The PCM or TCM receives the VSS input from the Output Shaft
Speed (OSS). The IPC monitors the VSS input from the PCM or TCM and commands the speedometer with a
corresponding movement of the pointer.
The IPC provides a tolerance which biases the speed indication and displays between 3% below and 7%
higher than actual vehicle speed. This means that with an actual vehicle speed of 96.6 km/h (60 mph), the
speedometer may indicate between 93.7-103.3 km/h (58.2-64.2 mph). Other factors that could potentially
affect the speedometer accuracy are incorrect tire size, tire size configuration and axle ratio configuration.
If the vehicle speed data is missing for 5 seconds or less or if the IPC receives invalid vehicle speed data for 5
seconds or less, the IPC defaults the speedometer to the last setting, based upon the last known good vehicle
speed message. If the IPC does not receive the vehicle speed data for more than 5 seconds, the IPC sets DTC
U0100:00 (non-hybrid) or U0101:00 (hybrid) in continuous memory and defaults the speedometer to 0 km/h
(0 mph). If the vehicle speed data received is deemed invalid by the IPC for 5 seconds or more, the IPC sets
DTC U0401:68 (non-hybrid) or U0402:68 and defaults the speedometer to 0 km/h (0 mph).
Factors that could potentially affect the accuracy of the speedometer are configurable items such as axle ratio
and tire size.
• Tire size configuration

• Axle ratio or driveline type configuration
• PCM concern
• IPC
PINPOINT TEST G: INCORRECT SPEEDOMETER INDICATION

G1 OBSERVE THE SPEEDOMETER
OPERATION
Yes
• Observe the speedometer while
driving the vehicle at various speeds No
and stopping frequently. INSTALL a new IPC . REFER to Instrument Panel
• Does the speedometer begin at 0 Cluster (IPC) in this section. TEST the system for
km/h (0 mph), indicate the different normal operation.
vehicle speeds and fully return to

the 0 km/h (0 mph) position when

the vehicle is stopped?
G2 CHECK THE TIRE SIZE
CONFIGURATION
Yes
• Enter the following diagnostic mode GO to G3 .
on the scan tool: Module
Programming . No
• NOTE: The correct tire size can be CONFIGURE the tire size. TEST the system for normal
found on the vehicle certification label operation.
on the LH B-pillar. Refer to Section
100-01 .
• Select programmable parameters and
verify that the vehicle has the correct
tire size according to the certification
label and the tire size is correctly
configured in the PCM.
• Is the tire size correct and is the tire
size parameter correctly
configured?
G3 CHECK THE AXLE RATIO OR
DRIVELINE TYPE CONFIGURATION
Yes
• Enter the following diagnostic mode GO to G4 .
on the scan tool: Module
Programming . No
• Select programmable parameters and CONFIGURE the axle ratio or driveline type. TEST the
verify that the axle ratio or driveline system for normal operation.
type is correctly configured in the
PCM.
• Is the axle ratio or driveline type
parameter correctly configured?
G4 RETRIEVE THE RECORDED DTCs
FROM THE PCM AND TCM KOEO
SELF-TEST
Yes
• Check for recorded PCM and TCM DIAGNOSE all PCM and TCM DTCs first. REFER to
DTCs from the Key ON Engine OFF Powertrain Control/Emissions Diagnosis (PC/ED)
(KOEO) self-test. manual.
No
GO to G5 .
G5 RETRIEVE THE RECORDED DTCs
Yes
• Check for recorded DTCs from the For DTC U0100:00 (non-hybrid), GO to Pinpoint Test
IPC self-test. BF .
For DTC U0100:01 (hybrid), GO to Pinpoint Test BG .
For DTC U0401:68 (non-hybrid) or U0402:68 (hybrid),

RETRIEVE and REPAIR all non-network DTCs in the
PINPOINT TEST G: INCORRECT SPEEDOMETER INDICATION 5215

PCM and other modules on the network. REFER to the

Powertrain Control/Emissions Diagnosis (PC/ED)
manual and Section 419-10 for a list of all DTCs.
For all other DTCs, REFER to DTC Charts in this

section.
No
GO to G6 .
G6 CARRY OUT THE IPC
SPEEDOMETER ACTIVE COMMAND
USING THE SCAN TOOL
Yes
on the scan tool: IPC DataLogger . No
• Select the IPC speedometer INSTALL a new IPC . REFER to Instrument Panel
(SPDOMETER) active command. Cluster (IPC) in this section. TEST the system for
Command the speedometer according normal operation.
to the following table while
monitoring the speedometer.
Speedometer
0% 0 km/h (0 mph)
10% 19 km/h (12
mph)
20% 39 km/h (24
mph)
30% 58 km/h (36
mph)
40% 77 km/h (48
mph)
50% 97 km/h (60
mph)
60% 116 km/h (72
mph)
70% 135 km/h (84
mph)
80% 154 km/h (96
mph)
90% 174 km/h (108
mph)
100% 193 km/h (120
mph)
• Does the speedometer indicate the

approximate speed according to the
PINPOINT TEST G: INCORRECT SPEEDOMETER INDICATION 5216

above specifications?
G7 CHECK THE PCM VSS PIDs
Yes
• Enter the following diagnostic mode The speedometer is operating correctly at this time.
on the scan tool: PCM DataLogger .
• Select the PCM vehicle speed (VSS) No
PID and monitor the PID while INSTALL a new IPC . REFER to Instrument Panel
driving the vehicle at 32 km/h (20 Cluster (IPC) in this section. TEST the system for
mph), 64 km/h (40 mph) and 97 km/h normal operation.
(60 mph).
• Does the speedometer indicate
between 31-34 km/h (19-21 mph),
63-69 km/h (39-43 mph) and 93-103
km/h (58-64 mph) at the 3 PCM PID
values?
Pinpoint Test H: The Odometer Is Inoperative
Normal Operation
The Instrument Panel Cluster (IPC) receives the odometer rolling count data from the PCM (non-hybrid) or
the Transmission Control Module (TCM) (hybrid) over the High Speed Controller Area Network (HS-CAN)
communication bus. The IPC monitors the odometer rolling count input and commands the odometer with a
display in the message center display area.
If the IPC does not receive the odometer rolling count data or if the rolling count data is deemed invalid for
less than 5 seconds, the IPC displays the mileage based upon the last known good input.
If the IPC does not receive the odometer rolling count data or if the rolling count data is deemed invalid from
the PCM for 5 seconds, the IPC sets DTC U0100:00 (non-hybrid) or U0101:00 (hybrid) in continuous
memory and defaults the odometer display to all dashes (-----).
If the Non-Volatile Memory (NVM) is corrupted, the message center displays ERROR.
NOTE: If DTC U0100:00 is set in the IPC , other observable symptoms may be an inoperative speedometer,
tachometer, temperature gauge.
• TCM (hybrid)
• IPC
PINPOINT TEST H: THE ODOMETER IS INOPERATIVE

H1 CHECK FOR
CORRUPTED NVM
Yes
• Ignition ON. INSTALL a new IPC . REFER to Instrument Panel Cluster (IPC) in

• Observe the message this section. TEST the system for normal operation.
center display area.
• Does the odometer No
display ERROR? GO to H2 .
H2 RETRIEVE THE
RECORDED DTCs FROM
THE PCM AND TCM KOEO
SELF-TEST
Yes
• Check for recorded PCM DIAGNOSE all PCM and TCM DTCs first. REFER to Powertrain
and TCM DTCs from the Control/Emissions Diagnosis (PC/ED) manual.
Key ON Engine OFF
(KOEO) self-test. No
• Are any DTCs GO to H3 .
recorded?
H3 RETRIEVE THE
RECORDED DTCs FROM
THE IPC SELF-TEST
Yes
• Check for recorded For DTC U0100:00 (non-hybrid), GO to Pinpoint Test BF .
DTCs from the IPC
self-test. For DTC U0101:00 (hybrid), GO to Pinpoint Test BG .
• Are any DTCs
recorded? For DTC U0401:68 (non-hybrid) or U0402:68 (hybrid), RETRIEVE
and REPAIR all non-network DTCs in the PCM and other modules on
the network. REFER to the Powertrain Control/Emissions Diagnosis
(PC/ED) manual and Section 419-10 for a list of all DTCs.
No
INSTALL a new IPC . REFER to Instrument Panel Cluster (IPC) in
this section. TEST the system for normal operation.
Pinpoint Test I: The Tachometer Is Inoperative
Normal Operation
The PCM uses the Crankshaft Position (CKP) sensor to measure the engine rpm. The PCM sends the
Instrument Panel Cluster (IPC) the data over the High Speed Controller Area Network (HS-CAN)
communication bus, to command the tachometer gauge according to the data.
The non-hybrid and hybrid tachometers appear differently but function essentially the same. The non-hybrid
gauge is an analog gauge with a needle that points to a specified area of the gauge depending on the data
received from the PCM. The hybrid gauge is a digital display that provides a bar, which indicates engine rpm
when the gas engine is running. When the vehicle transitions into electric vehicle mode, the EV gauge
replaces the tachometer. The hybrid tachometer is only displayed in the enlighten display mode.
If the engine rpm data is invalid for 5 seconds or less or if the IPC does not receive the engine rpm data for 5
seconds or less, the IPC defaults the tachometer to the last setting, based upon the last known good rpm
message. If the IPC does not receive the engine rpm data from the PCM for more than 5 seconds, the IPC sets
DTC U0100:00 in continuous memory and defaults the tachometer to 0 rpm. If the engine rpm data is deemed
PINPOINT TEST H: THE ODOMETER IS INOPERATIVE 5218

invalid by the IPC for 5 seconds or more, the IPC sets DTC U0401:68 and defaults the tachometer to 0 rpm.
• PCM
• IPC
PINPOINT TEST I: THE TACHOMETER IS INOPERATIVE

I1 CARRY OUT THE TACHOMETER ACTIVE
Yes
NOTE: On hybrid vehicles, verify that the IPC GO to I2 .
display mode is set to the enlighten mode
setting before beginning diagnostics. No
INSTALL a new IPC . REFER to Instrument
• Ignition ON. Panel Cluster (IPC) in this section. TEST the
• Enter the following diagnostic mode on the system for normal operation.
scan tool: IPC DataLogger .
• NOTE: On hybrid, make sure to set the scan
tool to 0 rpm before beginning this test.
• Select the IPC tachometer (TACH_IND) active
command. Command the tachometer according
to the following table while monitoring the
tachometer.
Tachometer
0% 0 rpm
50% 3,500 rpm
(non-hybrid)
3,000 rpm (hybrid)

100% 7,000 rpm
(non-hybrid)
6,000 rpm (hybrid)

0% 0 rpm
• Does the tachometer start at 0 rpm, move to

3,500 rpm, 7,000 rpm and then return to 0
rpm?

I2 RETRIEVE THE RECORDED DTCs FROM

Yes
• Check for recorded PCM DTCs from the Key DIAGNOSE all PCM DTCs first. REFER to
ON Engine OFF (KOEO) self-test. the Powertrain Control/Emissions Diagnosis
• Are any DTCs recorded? (PC/ED) manual.
No
GO to I3 .
I3 RETRIEVE THE RECORDED DTCs FROM
THE IPC SELF-TEST
Yes
• Check for recorded DTCs from the IPC For DTC U0100:00, GO to Pinpoint Test BF .
self-test.
• Are any DTCs recorded? For DTC U0401:68, RETRIEVE and REPAIR
all non-network DTCs in the PCM and other
modules on the network. REFER to the
(PC/ED) manual and Section 419-10 for a list
of all DTCs.

this section.
No
operation.
Pinpoint Test J: Incorrect Tachometer Indication
Normal Operation
The PCM uses the Crankshaft Position (CKP) sensor to measure the engine rpm. The PCM sends the
Instrument Panel Cluster (IPC) the data over the High Speed Controller Area Network (HS-CAN)
communication bus, to command the tachometer according to the data.
The non-hybrid and hybrid tachometers appear differently but function essentially the same. The non-hybrid
gauge is an analog gauge with a needle that points to a specified area of the gauge depending on the data
received from the PCM. The hybrid gauge is a digital display that provides a bar, which indicates engine rpm
when the gas engine is running. When the vehicle transitions into electric vehicle mode, the EV gauge
replaces the tachometer. The hybrid tachometer is only displayed in the enlighten display mode.
The hybrid requires two messages sent from the PCM to operate the tachometer. The first message is an
engine active message indicating that the vehicle is in the gas engine operating mode. The second message
required for the tachometer is the actual engine rpm data.
If the engine rpm data is invalid for 5 seconds or less or if the IPC does not receive the engine rpm data for 5
seconds or less, the IPC defaults the tachometer to the last setting, based upon the last known good rpm
message. If the IPC does not receive the engine rpm data from the PCM for more than 5 seconds, the IPC sets
DTC U0100:00 in continuous memory and defaults the tachometer to 0 rpm. If the engine rpm data is deemed
invalid by the IPC for 5 seconds or more, the IPC sets DTC U0401:68 and defaults the tachometer to 0 rpm.
PINPOINT TEST I: THE TACHOMETER IS INOPERATIVE 5220

• PCM concern
• IPC
PINPOINT TEST J: INCORRECT TACHOMETER INDICATION

J1 CARRY OUT THE TACHOMETER ACTIVE
Yes
NOTE: On hybrid vehicles, verify that the IPC display GO to J2 .
mode is set to the enlighten mode setting before beginning
diagnostics. No
INSTALL a new IPC . REFER to
• Ignition ON. Instrument Panel Cluster (IPC) in
• Enter the following diagnostic mode on the scan tool: IPC this section. TEST the system for
DataLogger . normal operation.
• NOTE: On hybrid, make sure to set the scan tool to 0 rpm
before beginning this test.
• Select the IPC tachometer (TACH_IND) active command.
Command the tachometer according to the following table
while monitoring the tachometer.
Tachometer Non-Hybrid Gauge Hybrid Gauge

Command Position Position
0% 0 rpm 0 rpm
10% 700 rpm 600 rpm
20% 1,400 rpm 1,200 rpm
30% 2,100 rpm 1,800 rpm
40% 2,800 rpm 2,400 rpm
50% 3,500 rpm 3,000 rpm
60% 4,200 rpm 3,600 rpm
70% 4,900 rpm 4,200 rpm
80% 5,600 rpm 4,800 rpm
90% 6,300 rpm 5,400 rpm
100% 7,000 rpm 6,000 rpm
• Does the tachometer indicate the approximate rpm

according to the above specification?
J2 RETRIEVE THE RECORDED DTCs FROM THE PCM
KOEO SELF-TEST

• Check for recorded PCM DTCs from the Key ON Engine Yes
OFF (KOEO) self-test. DIAGNOSE all PCM DTCs first.
• Are any DTCs recorded? REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
No
GO to J3 .
J3 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Yes
For DTC U0401:68, RETRIEVE

and REPAIR all non-network DTCs
in the PCM and other modules on
the network. REFER to the
Powertrain Control/Emissions
Diagnosis (PC/ED) manual and
Section 419-10 for a list of all DTCs.

No
GO to J4 .
J4 CHECK THE ENGINE RPM INPUT USING THE IPC
DEALER TEST MODE
Yes
• Ignition ON. The tachometer is operating
• Enter the IPC dealer test mode. correctly at this time.
• NOTE: The display below uses xxx's to represent a
numeric or alpha-numeric value. The value may display No
the same amount of characters represented by the xxx's or INSTALL a new IPC . REFER to
there may be more/less depending on the type of display. Instrument Panel Cluster (IPC) in
For example: TACHOMETER xxx RPM (non-hybrid) or this section. TEST the system for
Tachometer x rpm (hybrid) may display TACHOMETER normal operation.
650 RPM (non-hybrid) or Tachometer 650 rpm (hybrid).
• Scroll through the displays to TACHOMETER xxx RPM
(non-hybrid) or Tachometer x rpm (hybrid).
• Start the engine and operate the engine at 1,000, 1,500 and
2,000 rpm while monitoring both the tachometer and the
engine rpm input in the dealer test mode.
• Does the engine rpm input agree approximately with
the position of the tachometer indication?
Pinpoint Test K: The EV Gauge Is Inoperative (Hybrid)
PINPOINT TEST J: INCORRECT TACHOMETER INDICATION 5222

Normal Operation
The EV gauge is an extension of the tachometer display. When the vehicle shifts into electric vehicle mode or
the ignition is in the RUN position with the engine off, the EV gauge replaces the tachometer display in the
Instrument Panel Cluster (IPC). The IPC receives the EV gauge data from the PCM over the High Speed
Controller Area Network (HS-CAN) communication bus, and engages and commands the EV gauge
according to the data received. The EV gauge is only available in the enlighten display mode.
For the IPC to switch to the EV gauge, the PCM first stops providing the message indicating that the vehicle
is in engine active mode and begins sending electric power flow data to the IPC .
If the electric motor data is invalid for 5 seconds or less or if the IPC does not receive the electric motor data
for 5 seconds or less, the IPC defaults the EV gauge to the last setting, based upon the last known good
electric motor message. If the IPC does not receive the electric motor data from the PCM for more than 5
seconds, the IPC sets DTC U0100:00 in continuous memory and defaults the EV gauge to 0 rpm. If the
electric motor data is deemed invalid by the IPC for 5 seconds or more, the IPC sets DTC U0401:68 and
defaults the EV gauge to 0.
• PCM concern
• IPC
PINPOINT TEST K: THE EV GAUGE IS INOPERATIVE (HYBRID)
NOTE: The gas engine must be off with the vehicle operating in electric vehicle mode for the EV gauge to
operate.

K1 VERIFY THAT THE
IPC IS IN THE CORRECT
DISPLAY SETTING
Yes
• Ignition ON. GO to K2 .
• Using the setup menu,
verify that the IPC is in No
the enlighten display SET the display setting to enlighten mode.
mode.
• Is the IPC in the
enlighten display
mode?
K2 RETRIEVE THE
RECORDED DTCs FROM
THE PCM KOEO
SELF-TEST
Yes
• Check for recorded DIAGNOSE all PCM DTCs first. REFER to the Powertrain
PCM DTCs from the Control/Emissions Diagnosis (PC/ED) manual.
Key ON Engine OFF

(KOEO) self-test. No
• Are any DTCs GO to K3 .
recorded?
K3 RETRIEVE THE
RECORDED DTCs FROM
THE IPC SELF-TEST
Yes
• Check for recorded For DTC U0100:00, GO to Pinpoint Test BF .
DTCs from the IPC
self-test. For DTC U0401:68, RETRIEVE and REPAIR all non-network DTCs
• Are any DTCs in the PCM and other modules on the network. REFER to the
recorded? Powertrain Control/Emissions Diagnosis (PC/ED) manual and Section
419-10 for a list of all DTCs.
No
INSTALL a new IPC . REFER to Instrument Panel Cluster (IPC) in
Pinpoint Test L: The High Voltage Battery Gauge Is Inoperative (Hybrid)
Normal Operation
The Instrument Panel Cluster (IPC) provides 4 indication modes for the high voltage battery gauge depending
upon which display mode the IPC is set to display. Each display mode incrementally adds additional
functional indications. The first indication mode displays the current state of charge of the Battery Pack
Sensor Module (BPSM). The second and third indication modes indicate whether the BPSM is in the charge
or assist mode. When in charge mode, an up arrow is displayed at the top of the gauge. When in assist mode, a
down arrow is displayed at the bottom of the gauge. The fourth indication mode displays a circular set of
arrows around the battery and a brighter green arrow at the top of the gauge to indicate that the vehicle is in
regenerative braking mode.
The IPC requires multiple operational messages from 3 separate modules sent over the High Speed Controller
Area Network (HS-CAN) communication bus to control the high voltage battery gauge. The following table
provides a summary of the messages and the originating module.
High Voltage Battery Gauge

Operational Message Originating Module Indication Mode
BPSM Current state of charge mode
• Measured state of charge
BPSM Charge and assist mode
• Current
BPSM Charge and assist mode
• Voltage
Transmission Control Module Regenerative braking mode
• Motor speed slow (TCM)
ABS module Regenerative braking mode
PINPOINT TEST K: THE EV GAUGE IS INOPERATIVE (HYBRID) 5224

• Hybrid electric vehicle

torque modification
If the state of charge data is missing or invalid for less than 5 seconds, the IPC defaults the state of charge
indicator to the last state, based upon the last known good state of charge data received. If the state of charge
data is invalid for 5 seconds or more, the IPC sets DTC U0412:68 and defaults the state of charge indicator to
the full low position. If the state of charge data is missing for 5 seconds or more, the IPC sets DTC U0111:00
and defaults the state of charge indicator to the full low position.
If the current/voltage data is missing or invalid for less than 5 seconds, the IPC defaults the charge and assist
arrows to the last state, based upon the last known good current/voltage data received. If the current/voltage
data is invalid for 5 seconds or more, the IPC sets DTC U0412:68 and defaults the charge and assist arrows
off. If the current/voltage data is missing for 5 seconds or more, the IPC sets DTC U0111:00 and defaults the
charge and assist arrows off.
If the motor speed data is missing or invalid for less than 5 seconds, the IPC defaults the regenerative braking
symbol and up arrow to the last state, based upon the last known good motor speed slow message received. If
the motor speed data is invalid for 5 seconds or more, the IPC sets DTC U0402:68 and defaults the
regenerative braking symbol and up arrow off. If the motor speed data is missing for 5 seconds or more, the
IPC sets DTC U0101:00 and defaults the regenerative braking symbol and up arrow off.
If the torque modification data is missing or invalid for 5 seconds or more, the IPC defaults the regenerative
braking symbol and up arrow off. If the motor speed data is invalid for 5 seconds or more, the IPC sets DTC
U0415:68 and defaults the regenerative braking symbol and up arrow off. If the motor speed data is missing
for 5 seconds or more, the IPC sets DTC U0121:00 and defaults the regenerative braking symbol and up
arrow off.
• High voltage battery concern

• Transaxle concern
• ABS concern
• IPC
PINPOINT TEST L: THE HIGH VOLTAGE BATTERY GAUGE IS INOPERATIVE (HYBRID)

L1 RETRIEVE THE RECORDED DTCs
FROM THE BPSM SELF-TEST
Yes
• Check for recorded BPSM DTCs DIAGNOSE all BPSM DTCs first. REFER to Section
from the self-test. 414-03 .
No
GO to L2 .
FROM THE TCM SELF-TEST
Yes
• Check for recorded TCM DTCs from DIAGNOSE all TCM DTCs first. REFER to Section
the self-test. 307-01C .


No
GO to L3 .
FROM THE ABS MODULE SELF-TEST
Yes
• Check for recorded ABS module DIAGNOSE all ABS module DTCs first. REFER to
DTCs from the self-test. Section 206-09 .
No
GO to L4 .
Yes
• Check for recorded DTCs from the REFER to DTC Charts in this section.
IPC self-test.
INSTALL a new IPC . REFER to Instrument Panel
Cluster (IPC) in this section. TEST the system for normal
operation.
Pinpoint Test M: The Fuel Efficiency Gauge Is Inoperative (Hybrid)
Normal Operation
The Instrument Panel Cluster (IPC) receives the fuel usage data from the PCM over the High Speed
Controller Area Network (HS-CAN) communication bus. The IPC monitors the fuel usage inputs and
provides an instantaneous display of the miles per gallon.
• PCM concern
• Transmission Control Module (TCM) concern
• IPC
PINPOINT TEST M: THE FUEL EFFICIENCY GAUGE IS INOPERATIVE (HYBRID)

M1 VERIFY THAT THE IPC IS IN THE
CORRECT DISPLAY SETTING
Yes
• Ignition ON. GO to M2 .
• Using the setup menu, verify that the
IPC is in the enlighten, engage or No
empower display mode. SET the display setting to the enlighten, engage or
• Is the IPC in the enlighten, engage empower mode.
or empower display mode?
M2 RETRIEVE THE RECORDED
DTCs FROM THE PCM KOEO
SELF-TEST
PINPOINT TEST L: THE HIGH VOLTAGE BATTERY GAUGE IS INOPERATIVE (HYBRID) 5226
• Check for recorded PCM DTCs from Yes

the Key ON Engine OFF (KOEO) DIAGNOSE all PCM DTCs first. REFER to Powertrain
self-test. Control/Emissions Diagnosis (PC/ED) manual.
No
GO to M3 .
DTCs FROM THE TCM SELF-TEST
Yes
• Check for recorded TCM DTCs from DIAGNOSE all TCM DTCs first. REFER to Section
the self-test. 307-01C .
No
GO to M4 .
DTCs FROM THE IPC SELF-TEST
Yes
• Check for recorded DTCs from the For DTC U0100:00, GO to Pinpoint Test BF .
IPC self-test.
• Are any DTCs recorded? For DTC U0101:00, GO to Pinpoint Test BG .
No
Cluster (IPC) in this section. TEST the system for normal
operation.
Pinpoint Test N: The Accessory Power Gauge Is Inoperative (Hybrid)
Normal Operation
The accessory power gauge indicates the amount of non-propulsion electrical demands that the vehicle
accessories are placing on the electrical system. Examples of non-propulsion accessories are air conditioning,
lighting, audio and the rear window defroster. The accessory power gauge is only displayed in the empower
display mode. When in use, these accessories use up electrical power that reduces the overall stored energy
that could be used to drive the electric motor. The accessory power gauge indicates the amount of power the
accessories are using up. Thus a rising gauge indicates that there is an increasing demand on the available
power and a falling gauge indication indicates that the demand from the accessories is reduced.
The Instrument Panel Cluster (IPC) receives the accessory power data from the air conditioning control
module and the DC to DC Converter Control Module (DC/DC) over the High Speed Controller Area Network
(HS-CAN) communication bus.
The IPC requires multiple operational messages to control the accessory power gauge. The following table
provides a summary of the messages and the originating module.
Operational Message Originating Module

Air conditioning control module
PINPOINT TEST M: THE FUEL EFFICIENCY GAUGE IS INOPERATIVE (HYBRID) 5227

• Actual power
consumption
DC/DC
• DC to DC high voltage
current
DC/DC
• DC to DC high voltage
If the actual power consumption data is missing or invalid for less than 5 seconds, the IPC defaults the
accessory power gauge to the last state, based upon the last known good actual power consumption data
received. If the actual power consumption data is invalid for 5 seconds or more, the IPC sets DTC U040A:68
and defaults the accessory power gauge to the full low position. If the actual power consumption data is
missing for 5 seconds or more, the IPC sets DTC U010F:00 and defaults the accessory power gauge to the full
low position.
If the DC to DC current/voltage data is missing or invalid for less than 5 seconds, the IPC defaults the
accessory power gauge to the last state, based upon the last known good DC to DC current/voltage data
received. If the DC to DC current/voltage data is invalid for 5 seconds or more, the IPC sets DTC U0599:68
and defaults the accessory power gauge to the full low position. If the DC to DC current/voltage data is
missing for 5 seconds or more, the IPC sets DTC U0298:00 and defaults the accessory power gauge to the full
low position.
• Air conditioning control module

• DC/DC
• IPC
PINPOINT TEST N: THE ACCESSORY POWER GAUGE IS INOPERATIVE (HYBRID)

N1 VERIFY THAT THE IPC IS IN THE CORRECT
DISPLAY SETTING
Yes
• Ignition ON. GO to N2 .
• Using the setup menu, verify that the IPC is in the
empower display mode. No
• Is the IPC in the empower display mode? SET the display setting to empower mode.
N2 RETRIEVE THE RECORDED DTCs FROM THE
AIR CONDITIONING CONTROL MODULE
SELF-TEST
Yes
• Check for recorded air conditioning control module DIAGNOSE all air conditioning control
DTCs from the self-test. module DTCs first. REFER to Section
• Are any DTCs recorded? 307-01C .
No
GO to N3 .

DC/DC SELF-TEST
Yes
• Check for recorded DC/DC DTCs from the self-test. DIAGNOSE all DC/DC DTCs first.
• Are any DTCs recorded? REFER to Section 414-05 .
No
GO to N4 .
IPC SELF-TEST
Yes
• Check for recorded DTCs from the IPC self-test. REFER to DTC Charts in this section.
No
Instrument Panel Cluster (IPC) in this
operation.
Pinpoint Test O: The Vehicle Power Gauge Is Inoperative (Hybrid)
Normal Operation
The vehicle power gauge indicates the power demand when the transaxle is in DRIVE (D) range. The vehicle
power gauge is only displayed in the empower display mode. The vehicle power gauge display provides the
gasoline engine on/off threshold using a green box on the lower end of the gauge and a gauge display
indicating the amount of acceleration demand through the accelerator pedal. As the accelerator is pressed
during normal driving, the gauge display increases until the acceleration or power demand is great enough to
require the assistance of the gasoline engine.
When the power demand is low and the vehicle is in the electric vehicle mode, the EV display at the bottom of
the gauge illuminates. Under certain circumstances such as system warm up or battery charging, the gasoline
engine runs regardless of how low the power demand is from the driver. In this case, the green box on the
lower portion of the gauge indicating the gasoline engine on/off threshold is not displayed.
The Instrument Panel Cluster (IPC) receives the vehicle power data from the PCM and Battery Pack Sensor
Module (BPSM) over the High Speed Controller Area Network (HS-CAN) communication bus.
If the PCM data is missing or invalid for less than 5 seconds, the IPC defaults the vehicle power gauge to the
last state, based upon the last known good actual power consumption data received. If the PCM data is invalid
for 5 seconds or more, the IPC sets DTC U0401:68 and defaults the vehicle power gauge to the full low
position. If the PCM data is missing for 5 seconds or more, the IPC sets DTC U0100:00 and defaults the
vehicle power gauge to the full low position.
If the current/voltage data is missing or invalid for less than 5 seconds, the IPC defaults the vehicle power
gauge to the last state, based upon the last known good current/voltage data received. If the current/voltage
data is invalid for 5 seconds or more, the IPC sets DTC U0412:68 and defaults the vehicle power gauge to the
full low position. If the current/voltage data is missing for 5 seconds or more, the IPC sets DTC U0111:00 and
defaults the vehicle power gauge to the full low position.
• PCM
• BPSM
PINPOINT TEST N: THE ACCESSORY POWER GAUGE IS INOPERATIVE (HYBRID) 5229

• IPC
PINPOINT TEST O: THE VEHICLE POWER GAUGE IS INOPERATIVE (HYBRID)

O1 VERIFY THAT THE IPC IS IN
THE CORRECT DISPLAY SETTING
Yes
• Ignition ON. GO to O2 .
• Using the setup menu, verify that
the IPC is in the empower display No
mode. SET the display setting to empower mode.
• Is the IPC in the empower
display mode?
O2 RETRIEVE THE RECORDED
SELF-TEST
Yes
• Check for recorded PCM DTCs DIAGNOSE all PCM DTCs first. REFER to the Powertrain
from the Key ON Engine OFF Control/Emissions Diagnosis (PC/ED) manual.
(KOEO) self-test.
GO to O3 .
DTCs FROM THE BPSM SELF-TEST
Yes
No
GO to O4 .
Yes
IPC self-test.
INSTALL a new IPC . REFER to Instrument Panel Cluster
(IPC) in this section. TEST the system for normal
operation.
Pinpoint Test P: The Split Power Gauge Is Inoperative (Hybrid)
Normal Operation
The split power gauge is actually a dual gauge indication. The LH side of the gauge provides the propulsion
power supplied by the electric motor in the electric vehicle mode. The RH side of the gauge provides the
propulsion power supplied by the gasoline engine. When the vehicle is powered by the electric motor in
electric vehicle mode, the gauge illuminates the EV icon at the bottom of the gauge. The split power gauge is
only displayed in the engage display mode.

The Instrument Panel Cluster (IPC) receives the split power gauge data from the PCM and the Battery Pack
Sensor Module (BPSM) over the High Speed Controller Area Network (HS-CAN) communication bus.
The IPC requires multiple operational messages to control the split power gauge. The following table provides
a summary of the messages and the originating module.
Operational Message Originating Module

PCM
• Engine active
PCM
• Engine speed
PCM
• Hybrid Electric Vehicle (HEV) estimated engine
torque
BPSM
• Current
BPSM
• Voltage
If the PCM data is missing or invalid for less than 5 seconds, the IPC defaults the split power gauge to the last
state, based upon the last known good actual power consumption data received. If the PCM data is invalid for
5 seconds or more, the IPC sets DTC U0401:68 and defaults the split power gauge to the full low position. If
the PCM data is missing for 5 seconds or more, the IPC sets DTC U0100:00 and defaults the split power
gauge to the full low position.
If the current/voltage data is missing or invalid for less than 5 seconds, the IPC defaults the split power gauge
to the last state, based upon the last known good current/voltage data received. If the current/voltage data is
invalid for 5 seconds or more, the IPC sets DTC U0412:68 and defaults the split power gauge to the full low
position. If the current/voltage data is missing for 5 seconds or more, the IPC sets DTC U0111:00 and defaults
the split power gauge to the full low position.
• PCM concern
• High voltage battery concern
• IPC
PINPOINT TEST P: THE SPLIT POWER GAUGE IS INOPERATIVE (HYBRID)

P1 VERIFY THAT THE IPC IS IN
THE CORRECT DISPLAY SETTING
Yes
• Using the setup menu, verify that
the IPC is in the engage display No

mode. SET the display setting to engage mode.

• Is the IPC in the engage display
mode?
P2 RETRIEVE THE RECORDED
SELF-TEST
Yes
• Check for recorded PCM DTCs DIAGNOSE all PCM DTCs first. REFER to the Powertrain
from the Key ON Engine OFF Control/Emissions Diagnosis (PC/ED) manual.
(KOEO) self-test.
GO to P3 .
DTCs FROM THE BPSM SELF-TEST
Yes
No
GO to P4 .
Yes
IPC self-test.
INSTALL a new IPC . REFER to Instrument Panel Cluster
(IPC) in this section. TEST the system for normal
operation.
Pinpoint Test R: The Low Oil Pressure Warning Indicator Is Never/Always On (Non-Hybrid)
Normal Operation
The Instrument Panel Cluster (IPC) provides a reference voltage to the engine oil pressure switch. When the
oil pressure is within normal ranges, the engine oil pressure switch closes to ground, pulling the reference
voltage low in the IPC . The IPC senses the low reference voltage and turns off the low oil pressure warning
indicator. When the engine oil pressure is low, the engine oil pressure switch opens, sending the reference
voltage high in the IPC . The IPC senses the high voltage and turns the low oil pressure warning indicator on.

• Base engine oil pressure concern
• IPC
PINPOINT TEST P: THE SPLIT POWER GAUGE IS INOPERATIVE (HYBRID) 5232

PINPOINT TEST R: THE LOW OIL PRESSURE WARNING INDICATOR IS NEVER/ALWAYS ON (NON-HYBRID)
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to
Section 414-01 .

R1 CARRY OUT THE IPC INDICATOR LAMP
CONTROL ACTIVE COMMAND USING THE SCAN
TOOL
Yes
• Ignition ON. If the original symptom is the low oil
• Enter the following diagnostic mode on the scan pressure warning indicator is always on,
tool: IPC DataLogger . GO to R4 .
• Select the IPC low oil pressure warning indicator
(OIL_P_LOW) active command. Command the low If the original symptom is the low oil
oil pressure warning indicator on and off while pressure warning indicator is never on, GO
observing the low oil pressure warning indicator. to R2 .
• Does the low oil pressure warning indicator
illuminate when commanded on, and turn off No
when commanded off? GO to R7 .
R2 CHECK FOR A STUCK CLOSED ENGINE OIL
PRESSURE SWITCH
Yes
• Ignition OFF. INSTALL a new Engine Oil Pressure
• Disconnect: Engine Oil Pressure Switch C103 . (EOP) switch. REFER to Section 303-01A
• Ignition ON. (2.5L), Section 303-01B (3.0L) or Section
• Observe the low oil pressure warning indicator. 303-01C (3.5L). TEST the system for
• Does the low oil pressure warning indicator turn normal operation.
on?
No
GO to R3 .
R3 CHECK OIL PRESSURE INPUT CIRCUIT FOR A
SHORT TO GROUND
Yes
• Measure the resistance between the IPC C220-6, No
circuit CMC24 (GY), harness side and ground. REPAIR the circuit. TEST the system for
normal operation.
PINPOINT TEST R: THE LOW OIL PRESSURE WARNING INDICATOR IS NEVER/ALWAYS ON

5233
(NON-HY
R4 CHECK FOR A STUCK OPEN ENGINE OIL

PRESSURE SWITCH
Yes
• Ignition OFF. REMOVE the jumper wire. GO to R6 .
• Disconnect: Engine Oil Pressure Switch C103 .
• Connect a fused jumper wire between the engine oil No
pressure switch, C103-1, circuit CMC24 (GY), LEAVE the jumper wire connected. GO to
harness side and ground. R5 .
• Ignition ON.
• Observe the low oil pressure warning indicator.
• Does the low oil pressure warning indicator turn
off?
R5 CHECK OIL PRESSURE INPUT CIRCUIT FOR
AN OPEN
Yes
• Ignition OFF. REMOVE the jumper wire. GO to R7 .
• Disconnect: Negative Battery Cable .
• Disconnect: IPC C220 . No
• With the jumper wire in place, measure the REMOVE the jumper wire. REPAIR the
resistance between the IPC C220-6, circuit CMC24 circuit. TEST the system for normal
(GY), harness side and ground. operation.

R6 CHECK THE OIL PRESSURE
Yes
• Carry out the oil pressure test. Refer to Section INSTALL a new Engine Oil Pressure
303-00 . (EOP) switch. REFER to Section 303-01A
• Is the oil pressure within specification? (2.5L), Section 303-01B (3.0L) or Section
303-01C (3.5L). TEST the system for
normal operation.
No
REFER to Section 303-00 to continue
diagnosis of the low engine oil pressure
concern.
PINPOINT TEST R: THE LOW OIL PRESSURE WARNING INDICATOR IS NEVER/ALWAYS ON

5234
(NON-HY
R7 CHECK FOR CORRECT IPC OPERATION

Yes
♦ pushed-out pins
present. by a loose or corroded connector.
Pinpoint Test S: The Brake Warning Indicator is Never On
Normal Operation
The Instrument Panel Cluster (IPC) uses 3 basic messaged inputs to control the brake warning indicator. The
first 2 are the parking brake warning indicator switch and brake fluid level switch. The third is for the
Electronic Brake Distribution (EBD) and the brake booster vacuum sensor, controlled by the ABS module.
The parking brake warning indicator switch and the brake fluid level switch status are sent from the Smart
Junction Box (SJB) over the Medium Speed Controller Area Network (MS-CAN) communication bus. The
EBD message is sent from the ABS module over the High Speed Controller Area Network (HS-CAN)
communication bus lines. The parking brake warning indicator switch and brake fluid level switch are both
hardwired to the SJB . The parking brake warning indicator switch is case grounded and the brake fluid level
uses an external ground circuit.
The SJB provides a reference voltage to both the parking brake warning indicator switch and the brake fluid
level switch. When the parking brake is applied, the parking brake warning indicator switch closes to ground,
providing a ground to the SJB and pulling the parking brake input circuit low. When a low brake fluid level
condition exists, the low brake fluid level switch closes to ground through the ground circuit, pulling the brake
fluid level input circuit low. The SJB monitors the parking brake and the brake fluid level inputs sending the
IPC a message to turn the brake warning indicator on or when the parking brake is applied. When the ABS
module detects a base brake system concern or other ABS-related concerns that affect the EBD function, the
ABS module sends a message to the IPC to illuminate both the ABS warning indicator and the brake warning
indicator.

• Parking brake warning indicator switch
• Brake fluid level switch
• SJB
• IPC

PINPOINT TEST S: THE BRAKE WARNING INDICATOR IS NEVER ON
Section 414-01 .

S1 CARRY OUT THE IPC INDICATOR LAMP CONTROL
Yes
• Enter the following diagnostic mode on the scan tool: IPC
DataLogger . No
• Select the IPC brake warning indicator (PBA_LMP) active INSTALL a new IPC . REFER
command. Command the brake warning indicator on while to Instrument Panel Cluster
observing the brake warning indicator. (IPC) in this section. TEST the
• Does the brake warning indicator illuminate when system for normal operation.
commanded on?
S2 DETERMINE IF THE BRAKE WARNING INDICATOR
OPERATES WITH THE PARKING BRAKE
Yes
• Apply the parking brake while monitoring the brake warning GO to S6 .
indicator.
• Does the brake warning indicator illuminate with the No
parking brake applied? GO to S3 .
S3 CHECK THE PARKING BRAKE WARNING INDICATOR
SWITCH PID
Yes
• Enter the following diagnostic mode on the scan tool: SJB GO to S9 .
DataLogger .
• Select the SJB parking brake PID (PRK_BRK). Monitor the No
parking brake PID while applying the parking brake. GO to S4 .
• Does the PID agree with the parking brake position?
S4 CHECK THE PARKING BRAKE WARNING INDICATOR
SWITCH
Yes
• Disconnect: Parking Brake Warning Indicator Switch C306 . REMOVE the jumper wire.
• Connect a fused jumper wire between the parking brake warning INSTALL a new parking
indicator switch C306-1, circuit CMC25 (WH/VT), harness side brake warning indicator
and ground. switch. TEST the system for
normal operation.
No
REMOVE the jumper wire.
GO to S5 .
• Does the brake warning indicator illuminate?
PINPOINT TEST S: THE BRAKE WARNING INDICATOR IS NEVER ON 5236

S5 CHECK THE PARKING BRAKE SIGNAL CIRCUIT FOR AN

OPEN
Yes
• Disconnect: SJB C2280c . GO to S9 .
• Measure the resistance between the SJB C2280c-1, circuit
CMC25 (WH/VT), harness side and the parking brake warning No
indicator switch C306-1, circuit CMC25 (WH/VT), harness side REPAIR the circuit. TEST the
and ground. system for normal operation.

S6 CHECK THE BRAKE FLUID LEVEL SWITCH OPERATION
Yes
• Ignition OFF. REMOVE the jumper wire.
• Disconnect: Brake Fluid Level Switch C124 . INSTALL a new brake fluid
• Ignition ON. level switch. TEST the system
• Connect a fused jumper wire between the brake fluid level for normal operation.
switch C124-1, circuit CMC19 (GY/VT), harness side and the
brake fluid level switch C124-2, circuit GD121 (BK/YE), No
harness side. REMOVE the jumper wire.
GO to S7 .
• Does the brake warning indicator illuminate?

S7 CHECK THE BRAKE FLUID LEVEL SWITCH GROUND
CIRCUIT FOR AN OPEN
Yes
• Measure the resistance between the brake fluid level switch No
C124-2, circuit GD121 (BK/YE), harness side and ground. REPAIR the circuit. TEST the
PINPOINT TEST S: THE BRAKE WARNING INDICATOR IS NEVER ON 5237


S8 CHECK THE BRAKE FLUID LEVEL INPUT CIRCUIT FOR
AN OPEN
Yes
• Disconnect: SJB C2280f . GO to S9 .
• Measure the resistance between the SJB C2280f-9, circuit
CMC19 (GY/VT), harness side and the brake fluid level switch No
C124-1, circuit CMC19 (GY/VT), harness side. REPAIR the circuit. TEST the

S9 CHECK FOR CORRECT SJB OPERATION
Yes
• Disconnect all the SJB connectors. INSTALL a new SJB . REFER
• Check for: to Section 419-10 . TEST the
♦ damaged pins
• Connect all the SJB connectors and make sure they seat The system is operating
correctly. correctly at this time. The
connector.
Pinpoint Test T: The Brake Warning Indicator is Always On
Normal Operation
The Instrument Panel Cluster (IPC) uses 3 basic messaged inputs to control the brake warning indicator. The
first 2 are the parking brake warning indicator switch and brake fluid level switch. The third is for the
Electronic Brake Distribution (EBD) and the brake booster vacuum sensor, controlled by the ABS module.
The parking brake warning indicator switch and the brake fluid level switch status are sent from the Smart
Junction Box (SJB) over the Medium Speed Controller Area Network (MS-CAN) communication bus. The
EBD message is sent from the ABS module over the High Speed Controller Area Network (HS-CAN)
communication bus lines. The parking brake warning indicator switch and brake fluid level switch are both
hardwired to the SJB . The parking brake warning indicator switch is case grounded and the brake fluid level

uses an external ground circuit.
The SJB provides a reference voltage to both the parking brake warning indicator switch and the brake fluid
level switch. When the parking brake is applied, the parking brake warning indicator switch closes to ground,
providing a ground to the SJB and pulling the parking brake input circuit low. When a low brake fluid level
condition exists, the low brake fluid level switch closes to ground through the ground circuit, pulling the brake
fluid level input circuit low. The SJB monitors the parking brake and the brake fluid level inputs sending the
IPC a message to turn the brake warning indicator on or when the parking brake is applied. When the ABS
module detects a base brake system concern or other ABS-related concerns that affect the EBD function, the
ABS module sends a message to the IPC to illuminate both the ABS warning indicator and the brake warning
indicator.
If the brake fluid level or parking brake status messages are missing for more than 5 seconds, the IPC sets
DTC U0140:00 and defaults the brake warning indicator on. If the IPC does not receive the ABS status
message or the EBD message from the ABS module for more than 5 seconds, the IPC sets DTC U0121:00
and defaults the ABS warning indicator on.
• DTC B2479 (Park Brake Switch Circuit Short to Ground) - an on-demand DTC that sets when the
SJB detects a short to ground on the parking brake warning indicator switch input circuit.
• DTC C1125 (Brake Fluid Level Sensor Input Circuit Failure) - a continuous and on-demand DTC that
sets in the SJB if the SJB detects a short to ground on the brake fluid level input circuit.
NOTE: If DTC U0140:00 is set in the IPC , other symptoms may also be present such as Tire Pressure
Monitoring System (TPMS), instrument panel backlighting, and door ajar indication.
NOTE: Whenever the IPC receives an EBD message from the ABS module, the IPC illuminates both the
brake warning indicator and the ABS warning indicator simultaneously.

• Parking brake warning indicator switch
• Brake fluid level switch
• ABS concern
• SJB
• IPC
PINPOINT TEST T: THE BRAKE WARNING INDICATOR IS ALWAYS ON

T1 CARRY OUT THE IPC INDICATOR LAMP CONTROL
Yes
• Ignition ON. GO to T2 .
DataLogger . No
• Select the IPC brake warning indicator (PBA_LMP) active INSTALL a new IPC . REFER to
command. Command brake warning indicator on and off Instrument Panel Cluster (IPC) in
while observing the brake warning indicator. this section. TEST the system for
PINPOINT TEST T: THE BRAKE WARNING INDICATOR IS ALWAYS ON 5239

• Does the brake warning indicator turn off when normal operation.
commanded off?
T2 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Yes
• Check for recorded DTCs from the IPC self-test. For DTC U0140:00, GO to
• Are any DTCs recorded? Pinpoint Test BM .
For DTC U0121:00, GO to

Pinpoint Test BK .
For all other DTCs, REFER to

DTC Charts in this section.
No
GO to T3 .
T3 RETRIEVE THE RECORDED DTCs FROM THE ABS
MODULE SELF-TEST
Yes
• Check for recorded DTCs from the ABS module self-test. REFER to Section 206-09 .
No
GO to T4 .
T4 RETRIEVE THE RECORDED DTCs FROM THE SJB
SELF-TEST
Yes
• Check for recorded DTCs from the SJB self-test. GO to T5 .
• Is DTC B2479 recorded?
No
GO to T8 .
T5 CHECK THE PARKING BRAKE WARNING
INDICATOR SWITCH PID
Yes
• Enter the following diagnostic mode on the scan tool: SJB GO to T10 .
DataLogger .
• Select the SJB parking brake PID (PRK_BRAKE). Monitor No
the parking brake PID while applying and releasing the GO to T6 .
parking brake.
• Does the PID agree with the parking brake position?
T6 CHECK THE PARKING BRAKE WARNING
INDICATOR SWITCH
Yes
• Disconnect: Parking Brake Warning Indicator Switch C306 . INSTALL a new parking brake
• Enter the following diagnostic mode on the scan tool: SJB warning indicator switch. CLEAR
DataLogger . the DTCs. REPEAT the self-test.
• Select the SJB parking brake PID (PRK_BRAKE). Monitor
the parking brake PID. No
• Does the PID indicate the parking brake is released or GO to T7 .
off?
T7 CHECK CIRCUIT CMC25 (WH/VT) FOR A SHORT TO
GROUND


• Disconnect: SJB C2280c . GO to T10 .
• Measure the resistance between the SJB C2280c-1, circuit
CMC25 (WH/VT), harness side and ground. No
REPAIR the circuit. CLEAR the

T8 CHECK THE BRAKE WARNING INDICATOR USING
THE BRAKE FLUID LEVEL SWITCH
Yes
• Ignition OFF. GO to T9 .
• Disconnect: Brake Fluid Level Switch C124 .
• Ignition ON. No
• Enter the following diagnostic mode on the scan tool: SJB INSTALL a new brake fluid level
Self-Test . switch. CLEAR the DTCs.
• Clear the SJB DTCs. Repeat the self-test. REPEAT the self-test.
• Is DTC C1125 still present?
T9 CHECK THE BRAKE FLUID LEVEL INPUT CIRCUIT
Yes
• Ignition OFF. GO to T10 .
• Disconnect: SJB C2280f .
• Measure the resistance between the SJB C2280f-9, circuit No
CMC19 (GY/VT), harness side and ground. REPAIR the circuit. TEST the

T10 CHECK FOR CORRECT SJB OPERATION
Yes
♦ damaged pins
• Connect all the SJB connectors and make sure they seat The system is operating correctly
correctly. at this time. The concern may
• Operate the system and verify that the concern is still present. have been caused by a loose or

Pinpoint Test U: The ABS Warning Indicator Is Never/Always On
Normal Operation
The ABS module provides the ABS status to the Instrument Panel Cluster (IPC) over the High Speed
Controller Area Network (HS-CAN) communication bus. If a fault condition exists in the ABS, the ABS
module sends the IPC a command to turn on the ABS warning indicator.
If the ABS status message is missing for less than 5 seconds, the ABS warning indicator remains in the last
indication mode (on or off) based upon the last known good message received. If the ABS status message is
missing for more than 5 seconds, the IPC sets DTC U0121:00 and defaults the ABS warning indicator on.
• ABS module
• IPC
PINPOINT TEST U: THE ABS WARNING INDICATOR IS NEVER/ALWAYS ON

U1 CARRY OUT THE IPC INDICATOR LAMP
TOOL
Yes
• Ignition ON. GO to U2 .
• Select the IPC ABS warning indicator INSTALL a new IPC . REFER to Instrument
(ABS_LAMP) active command. Command the Panel Cluster (IPC) in this section. TEST the
ABS warning indicator on then off. Observe the system for normal operation.
ABS warning indicator.
• Does the ABS warning indicator turn on when
commanded on and turn off when commanded
off?
U2 RETRIEVE THE RECORDED DTCs FROM
THE IPC SELF-TEST
Yes
• Check for recorded DTCs from the IPC self-test. For DTC U0121:00, GO to Pinpoint Test
• Are any DTCs recorded? BK .

in this section.
No
GO to U3 .
U3 RETRIEVE THE RECORDED DTCs FROM
THE ABS MODULE SELF-TEST
Yes

• Check for recorded DTCs from the ABS module

self-test. No
• Are any DTCs recorded? INSTALL a new ABS module. REFER to
Section 206-09 . TEST the system for
normal operation.
Pinpoint Test V: The Stability/Traction Control Indicator Is Never/Always On
Normal Operation
The Instrument Panel Cluster (IPC) receives the stability/traction control data from the ABS module over the
High Speed Controller Area Network (HS-CAN) communication bus. The stability/traction control indicator
flashes when the vehicle stability/traction control is in active mode or is being controlled by the ABS module.
The stability/traction control indicator turns on steady if a fault condition exists in the stability/traction control
system. The IPC monitors the stability/traction control message from the ABS module and either flashes the
stability/traction control indicator or turns it on steady depending on the condition.
Whenever a fault is detected in the ABS module and the ABS warning indicator is illuminated, the
stability/traction control indicator also illuminates and stability/traction control is disabled.
If the stability/traction control status message is missing for less than 5 seconds, the stability/traction control
indicator remains in the last indication mode (on or off) based upon the last known good message received. If
the stability/traction control message is missing for more than 5 seconds, the IPC sets DTC U0121:00 in
continuous memory and defaults the stability/traction control indicator on.
• Stability/traction control concern

• ABS module
• IPC
PINPOINT TEST V: THE STABILITY/TRACTION CONTROL INDICATOR IS NEVER/ALWAYS ON

V1 CARRY OUT THE IPC INDICATOR LAMP CONTROL
Yes
• Ignition ON. GO to V2 .
DataLogger . No
• Enter the IPC active command mode and select the INSTALL a new IPC .
stability/traction control indicator (TC/IVD/RSCLMP) active REFER to Instrument Panel
command. Command the stability/traction control indicator on Cluster (IPC) in this section.
and off while observing the stability/traction control indicator. TEST the system for normal
• Does the stability/traction control indicator illuminate when operation.
commanded on, and turn off when commanded off?
V2 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Yes
PINPOINT TEST U: THE ABS WARNING INDICATOR IS NEVER/ALWAYS ON 5243

• Are any DTCs recorded? Pinpoint Test BK .
For all other DTCs, REFER

to DTC Charts in this section.
No
GO to V3 .
V3 RETRIEVE THE RECORDED DTCs FROM THE ABS
MODULE SELF-TEST
Yes
• Check for recorded DTCs from the ABS module self-test. REFER to Section 206-09 .
No
INSTALL a new ABS
module. REFER to Section
206-09 . TEST the system for
normal operation.
Pinpoint Test W: The Stability/Traction Control Disabled Indicator Is Never/Always On
Normal Operation
The traction control switch is hardwired to the Instrument Panel Cluster (IPC). When the traction control
switch is pressed, the IPC sends a message to the ABS module over the High Speed Controller Area Network
(HS-CAN) communication bus indicating that the traction control switch has been pressed. The ABS module
either disables or enables the stability/traction control system and sends a message back to the IPC to turn on
or off the stability/traction control disabled indicator based upon the system state.
When a MyKey® programmed key is in use and the AdvanceTrac® on feature is configured always on, the
stability/traction control system cannot be disabled and the stability/traction control indicator does not turn on
when the traction control disable button is pressed. The stability/traction control indicator still functions
normally to indicate a stability/traction control system fault and a stability/traction control active event.
If the traction control switch state message is missing for less than 5 seconds, the stability/traction control
disabled indicator remains in the last indication mode (on or off) based upon the last known good message
received. If the traction control switch state message is missing for more than 5 seconds, the IPC sets DTC
U0121:00 in continuous memory and defaults the stability/traction control disabled indicator off.
• A MyKey® programmed key is in use

• Stability/traction control cannot be disabled
• ABS module
• IPC
PINPOINT TEST W: THE STABILITY/TRACTION CONTROL DISABLED INDICATOR IS NEVER/ALWAYS ON
Result / Action
Test Step
to Take
W1 CARRY OUT THE IPC INDICATOR LAMP Yes
CONTROL ACTIVE COMMAND USING THE GO to W2
PINPOINT TEST V: THE STABILITY/TRACTION CONTROL INDICATOR IS NEVER/ALWAYS5244

ON
SCAN TOOL • Ignition .

ON.
• Enter the No
following INSTALL
diagnostic a new IPC
mode on . REFER
the scan to
tool: IPC Instrument
DataLogger Panel
. Cluster
• Enter the (IPC) in
IPC active this
command section.
mode and TEST the
select the system for
stability/traction
normal
control operation.
disabled
indicator
(STAB_TC_LMP)
active
command.
Command
the
stability/traction
control
disabled
indicator
on and off
while
observing
the
stability/traction
control
disabled
indicator.
• Does the
stability/traction
control
disabled
indicator
illuminate
when
commanded
on and
turn off
when
commanded
off?
W2 CHECK FOR THE KEY TYPE
Yes
• Check if the key is a MyKey® programmed key GO to W3 .
or an administrator key. Refer to a
target="_parent" No
PINPOINT TEST W: THE STABILITY/TRACTION CONTROL DISABLED INDICATOR IS NEVER/ALWAYS

5245
href="SCS~us~en~file=SCSSJ1BL.HTM~gen~ref.HTM" If the MyKey®

>Section 419-01B . AdvanceTrac®
• Is the key an administrator key? on feature is
configured
always on, the
system is
normal. The
stability/traction
control system
cannot be
disabled when
the
AdvanceTrac®
on feature is
configured
always on. If the
MyKey®
AdvanceTrac®
on feature is not
configured
always on, GO
to W3 .
W3 CHECK THE TRACTION CONTROL INPUT
TO THE IPC
Yes
• Enter the following diagnostic mode on the scan GO to W4 .
tool: IPC DataLogger .
• Select the IPC stability/traction control indicator No
PID (STAB_CTRL_SW). REFER to
• Monitor the traction control PID while pressing Section 206-09
and releasing the traction control disable switch. to diagnose the
• Does the stability/traction control PID read traction control
RELEASED when the button is released and system cannot be
DEPRESSED when the button is pressed? disabled.
W4 RETRIEVE THE RECORDED DTCs FROM
THE IPC SELF-TEST
Yes
• Check for recorded DTCs from the IPC self-test. For DTC
• Are any DTCs recorded? C0089:11,
REFER to
Section 206-09 .
For DTC
U0121:00, GO
to Pinpoint Test
BK .
For all other

DTCs, REFER
to DTC Charts
in this section.
No
PINPOINT TEST W: THE STABILITY/TRACTION CONTROL DISABLED INDICATOR IS NEVER/ALWAYS

5246
GO to W5 .
W5 RETRIEVE THE RECORDED DTCs FROM
THE ABS MODULE SELF-TEST
Yes
• Check for recorded DTCs from the ABS module REFER to
self-test. Section 206-09 .
No
INSTALL a new
ABS module.
REFER to
Section 206-09 .
TEST the system
for normal
operation.
Pinpoint Test X: The Safety Belt Warning Indicator Is Never/Always On
Normal Operation
The Restraints Control Module (RCM) monitors the safety belt position through the safety belt buckle switch.
The RCM provides the safety belt buckle status to the Instrument Panel Cluster (IPC) over the High Speed
Controller Area Network (HS-CAN) communication bus.
If the safety belt status message is missing for less than 5 seconds, the safety belt warning indicator remains in
the last indication mode (on or off) based upon the last known good message received. If the safety belt status
message is missing for 5 seconds or more, the IPC sets DTC U0151:00 and defaults the safety belt warning
indicator off.
• RCM
• IPC
PINPOINT TEST X: THE SAFETY BELT WARNING INDICATOR IS NEVER/ALWAYS ON

X1 CARRY OUT THE IPC INDICATOR LAMP
TOOL
Yes
• Ignition ON. GO to X2 .
IPC DataLogger . No
• Select the IPC safety belt warning indicator INSTALL a new IPC . REFER to
(SBLT_LAMP) active command. Command the Instrument Panel Cluster (IPC) in this
safety belt warning indicator on and off while section. TEST the system for normal
observing the safety belt warning indicator. operation.
• Does the safety belt warning indicator illuminate
when commanded on, and turn off when

commanded off?
X2 RETRIEVE THE RECORDED DTCs FROM THE
IPC SELF-TEST
Yes
• Check for recorded DTCs from the IPC self-test. GO to Pinpoint Test BN .
• Is DTC U0151:00 recorded?
No
GO to X3 .
X3 RETRIEVE THE RECORDED DTCs FROM THE
RCM SELF-TEST
Yes
• Check for recorded DTCs from the RCM self-test. REFER to Section 501-20B .
No
INSTALL a new RCM . REFER to
Section 501-20B . TEST the system for
normal operation.
Pinpoint Test Y: The Air Bag Warning Indicator Is Never/Always On
Normal Operation
The Instrument Panel Cluster (IPC) receives the Supplemental Restraint System (SRS) status from the
Restraints Control Module (RCM) over the High Speed Controller Area Network (HS-CAN) communication
bus. If an SRS concern is detected, the RCM sets a DTC and sends a message to the IPC to turn on the air bag
warning indicator.
If the SRS status message is missing for less than 5 seconds, the air bag warning indicator remains in the last
indication mode (on or off) based upon the last known good message received. If the SRS status message is
missing for more than 5 seconds, the IPC sets DTC U0151:00 and defaults the air bag warning indicator on.
• RCM
• IPC
PINPOINT TEST Y: THE AIR BAG WARNING INDICATOR IS NEVER/ALWAYS ON

Y1 CARRY OUT THE IPC AIR BAG WARNING
INDICATOR ACTIVE COMMAND USING THE SCAN
TOOL
Yes
• Ignition ON. GO to Y2 .
IPC DataLogger . No
• Select the IPC air bag warning indicator INSTALL a new IPC . REFER to
(AIRBAG_LMP) active command. Command the air Instrument Panel Cluster (IPC) in this
bag warning indicator on and off while observing the section. TEST the system for normal
air bag warning indicator. operation.
PINPOINT TEST X: THE SAFETY BELT WARNING INDICATOR IS NEVER/ALWAYS ON 5248

• Does the air bag warning indicator illuminate

commanded off?
Y2 RETRIEVE THE RECORDED DTCs FROM THE
RCM SELF-TEST
Yes
• Check for recorded DTCs from the RCM self-test. REFER to Section 501-20B .
No
GO to Y3 .
Y3 RETRIEVE THE RECORDED DTCs FROM THE
IPC SELF-TEST
Yes
• Are any DTCs recorded? BN .

No
INSTALL a new RCM . REFER to
Section 501-20B . TEST the system for
normal operation.
Pinpoint Test Z: The Anti-Theft Indicator Is Never/Always On
Normal Operation
The Instrument Panel Cluster (IPC) interacts with the PCM (non-hybrid) or Transmission Control Module
(TCM) (hybrid) and controls the Passive Anti-Theft System (PATS) function. The IPC controls the anti-theft
indicator based upon the status of the PATS .
The anti-theft indicator proves out for 3 seconds when the key is turned to the ON or START position. If there
is a PATS concern, the anti-theft indicator either flashes rapidly or glows steadily (for more than 3 seconds)
when the ignition is switched to the ON or START mode. The PATS also flashes the anti-theft indicator every
2 seconds at ignition off to act as a visual theft deterrent for all vehicles.
• PATS concern
• IPC
PINPOINT TEST Z: THE ANTI-THEFT INDICATOR IS NEVER/ALWAYS ON

Z1 CHECK THE ANTI-THEFT INDICATOR
OPERATION
Yes
• Ignition ON. GO to Z2 .
PINPOINT TEST Y: THE AIR BAG WARNING INDICATOR IS NEVER/ALWAYS ON 5249


tool: IPC DataLogger. INSTALL a new IPC . REFER to Instrument
• Select the IPC anti-theft indicator (THEFT_LMP) Panel Cluster (IPC) in this section. TEST the
active command. Command the anti-theft system for normal operation.
indicator on and off while observing the anti-theft
indicator.
• Does the anti-theft indicator illuminate when
commanded on and turn off when commanded
off?
Z2 RETRIEVE THE RECORDED DTCs FROM
Yes
• Check for recorded IPC DTCs from the REFER to Section 419-01B (non-hybrid) or
continuous self-test. Section 419-01C (hybrid).
• Are any PATS -related DTCs recorded?
No
Panel Cluster (IPC) in this section. TEST the
Pinpoint Test AA: The Door/Hood Ajar Warning Indicator Is Never/Always On (Fusion Non-Hybrid)
Normal Operation
The Instrument Panel Cluster (IPC) receives the door/hood ajar status for the LH front door, RH front door,
LH rear door, the RH rear door and hood from the Smart Junction Box (SJB) over the Medium Speed
Controller Area Network (MS-CAN) communication bus. When the IPC receives a message from the SJB that
the hood or one or more doors is open or ajar, the IPC turns on the door/hood ajar warning indicator.
If the door/hood ajar status message is missing for less than 5 seconds, the door/hood ajar warning indicator
remains in the last indication mode (on or off) based upon the last known good message received. If the
door/hood ajar status message is missing for more than 5 seconds, the IPC sets DTC U0140:00 and defaults
the door/hood ajar warning indicator on.
NOTE: If DTC U0140:00 is set in the SJB , other symptoms may also be present in the IPC such as high
beam indicator, RH/LH turn indicators, instrument panel backlighting and Tire Pressure Monitoring System
(TPMS).
• Interior lighting concern

• SJB
• IPC
PINPOINT TEST AA: THE DOOR/HOOD AJAR WARNING INDICATOR IS NEVER/ALWAYS ON (FUSION
NON-HYBRID)
PINPOINT TEST Z: THE ANTI-THEFT INDICATOR IS NEVER/ALWAYS ON 5250

AA1 CHECK THE INTERIOR LIGHTING OPERATION

Yes
• Open and close each door while monitoring the courtesy GO to AA2 .
lamps.
• Do the courtesy lamps operate correctly with each No
door? REFER to Section 417-02 .
AA2 CHECK THE HOOD AJAR SWITCH STATUS PID
Yes
• Ignition ON. GO to AA3
• Enter the following diagnostic mode on the scan tool: SJB
DataLogger . No
• Select the SJB hood ajar switch PID (HOOD_SW). Monitor REFER to Section 419-01A to
the PID with the hood closed and open. diagnose the hood ajar switch
• Does the PID agree with the status of the hood? circuit.
AA3 CARRY OUT THE IPC DOOR/HOOD AJAR
WARNING INDICATOR ACTIVE COMMAND USING THE
SCAN TOOL
Yes
• Ignition ON. GO to AA4 .
DataLogger . No
• Select the IPC door ajar warning indicator (DOOR_AJAR) INSTALL a new IPC . REFER to
active command. Command the door ajar warning indicator Instrument Panel Cluster (IPC) in
on and off while observing the door ajar warning indicator. this section. TEST the system for
• Does the door ajar warning indicator illuminate when normal operation.
AA4 RETRIEVE THE RECORDED DTCs FROM THE
CONTINUOUS IPC SELF-TEST
Yes
• Check for recorded IPC DTCs from the continuous GO to Pinpoint Test BM .
self-test.
• Is DTC U0140:00 recorded? No
GO to AA5 .
AA5 RETRIEVE THE RECORDED DTCs FROM THE SJB
SELF-TEST
Yes
• Check for recorded DTCs from the SJB self-test. REFER to the Diagnostic Trouble
• Are any SJB DTCs recorded? Code (DTC) Chart in Section
419-10 .
No
INSTALL a new SJB . REFER to
Section 419-10 . TEST the system
Pinpoint Test AB: The LH/RH Turn Or High Beam Indicator Is Never/Always On
Normal Operation
When the multifunction switch is in the LH or RH TURN position or if the high beams are on, a message is
sent to the Instrument Panel Cluster (IPC) from the Smart Junction Box (SJB) over the Medium Speed
PINPOINT TEST AA: THE DOOR/HOOD AJAR WARNING INDICATOR IS NEVER/ALWAYS ON

5251
(FUSION
Controller Area Network (MS-CAN) communication bus. The IPC upon receipt of the LH/RH turn or high
beam on message, flashes the LH or RH turn signal indicator on and off or illuminates the high beam
indicator.
• Turn signal concern

• High beam concern
• SJB
• IPC
PINPOINT TEST AB: THE LH/RH TURN OR HIGH BEAM INDICATOR IS NEVER/ALWAYS ON

AB1 DETERMINE THE FAULT CONDITION
Yes
• Place the headlamps in the HIGH BEAM position. GO to AB4 .
• Ignition ON.
• Observe the high beam indicator. No
• Does the high beam indicator illuminate? LEAVE the headlamps in the
HIGH BEAM position. GO to
AB2 .
AB2 CHECK THE HIGH BEAM HEADLAMPS OPERATION
Yes
• Observe the high beam headlamps. GO to AB3 .
• Do the high beam headlamps operate correctly?
No
AB3 CARRY OUT THE IPC INDICATOR LAMP CONTROL
Yes
• Turn off the headlamps. GO to AB6 .
DataLogger . No
• Select the IPC high beam indicator (HIGH_BEAM). INSTALL a new IPC . REFER
Command the high beam indicator on and off while observing to Instrument Panel Cluster
the high beam indicator. (IPC) in this section. TEST the
• Does the high beam indicator illuminate when commanded system for normal operation.
on, and turn off when commanded off?
AB4 CHECK THE LH OR RH TURN SIGNAL LAMPS
OPERATION
Yes
• Ignition ON. GO to AB5 .
• Operate the LH or RH turn signal. Observe the exterior LH or
RH turn lamps. No
• Do the turn signal lamps operate correctly? REFER to Section 417-01 .
AB5 CARRY OUT THE IPC INDICATOR LAMP CONTROL
Yes
GO to AB6 .


DataLogger . No
• Select the IPC RH or LH turn signal indicator (RH_TURN_L) INSTALL a new IPC . REFER
or (LH_TURN_L) active command. Command the RH or LH to Instrument Panel Cluster
turn signal indicator on and off while observing the LH or RH (IPC) in this section. TEST the
turn signal indicator. system for normal operation.
• Does the LH or RH turn signal indicator illuminate when
AB6 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Yes
• Are any DTCs recorded? Pinpoint Test BM .
For all other DTCs, REFER to

DTC Charts in this section.
No
INSTALL a new SJB . REFER
to Section 419-10 . TEST the
Pinpoint Test AC: The Tire Pressure Monitoring System (TPMS) Warning Indicator Is Never/Always
On
Normal Operation
The Instrument Panel Cluster (IPC) receives the Tire Pressure Monitoring System (TPMS) messages from the
Smart Junction Box (SJB) over the Medium Speed Controller Area Network (MS-CAN) communication bus.
If the SJB determines that the tire pressure has exceeded the low tire pressure limits, a message is sent to the
IPC to turn the TPMS warning indicator on. If a TPMS fault condition exists, the SJB sends a message to the
IPC to flash the TPMS warning indicator for 75 seconds then the IPC turns the indicator on steady. If the
TPMS is in the TPMS sensor training mode, the SJB sends a command to the IPC to flash the TPMS warning
indicator throughout the procedure.
If the TPMS status message is missing or invalid for less than 5 seconds, the IPC defaults the TPMS warning
indicator to the last setting (on or off), based upon the last known good message received. If the TPMS status
message is missing for more than 5 seconds, DTC U0140:00 sets and the TPMS warning indicator flashes for
approximately 75 seconds then turns the indicator on steady. If the message is invalid for more than 5
seconds, the IPC sets DTC U0430:068 (non-hybrid) or U0422:68 (hybrid) and flashes the TPMS warning
indicator for approximately 75 seconds then turns the indicator on steady.
NOTE: If DTC U0140:00 is set in the SJB , other symptoms may also be present such as high beam indicator,
RH/LH turn indicators, instrument panel backlighting, and door ajar indicator.
• Tire pressure
• TPMS concern
• SJB
• IPC
PINPOINT TEST AB: THE LH/RH TURN OR HIGH BEAM INDICATOR IS NEVER/ALWAYS ON
5253
PINPOINT TEST AC: THE TPMS WARNING INDICATOR IS NEVER/ALWAYS ON

AC1 CHECK THE TIRE PRESSURE
Yes
• Verify that the tire pressure in all tires meets the
GO to AC2 .
recommended tire pressures on the vehicle
certification label. Refer to Section 100-01 . No
• Do all the tires meet the recommended tire CORRECT the tire pressures. TEST the
pressures? system for normal operation.
AC2 CARRY OUT THE IPC INDICATOR LAMP
TOOL
Yes
• Ignition ON. GO to AC3 .
• Select the TPMS warning indicator INSTALL a new IPC . REFER to
(TPMWARN_LMP) active command. Command Instrument Panel Cluster (IPC) in this
the TPMS warning indicator on and off while section. TEST the system for normal
observing the TPMS warning indicator. operation.
• Does the TPMS warning indicator illuminate
when commanded on and turn off when
commanded off?
AC3 RETRIEVE THE RECORDED DTCs FROM
THE IPC SELF-TEST
Yes
• Check for recorded IPC DTCs from the continuous For DTC U0430:68 or DTC U0422:68,
self-test. RETRIEVE and REPAIR all non-network
• Are any DTCs recorded? DTCs in the SJB and all other modules on
the network. REFER to Section 419-10 for
a list of all DTCs.

in this section.
No
GO to AC4 .
AC4 RETRIEVE THE RECORDED DTCs FROM
THE SJB SELF-TEST
Yes
• Check for recorded DTCs from the SJB self-test. REFER to Section 419-10 for correct
• Are any DTCs recorded? navigation of the DTC.
No
INSTALL a new SJB . REFER to Section
419-10 . TEST the system for normal
operation.
Pinpoint Test AD: The Charging System Warning Indicator Is Never/Always On (Fusion Non-Hybrid)
PINPOINT TEST AC: THE TPMS WARNING INDICATOR IS NEVER/ALWAYS ON 5254

Normal Operation
The charging system indicator is controlled by the Instrument Panel Cluster (IPC) based upon data received
from the PCM over the High Speed Controller Area Network (HS-CAN) communication bus.
If the charging system message is missing for less than 5 seconds, the charging system indicator remains in
the last indication mode (on or off). If the charging system message is missing for more than 5 seconds, the
IPC sets DTC U0100:00 in continuous memory and defaults the charging system warning indicator on.
tachometer or odometer.
• Charging system concern

• PCM
• IPC
PINPOINT TEST AD: THE CHARGING SYSTEM WARNING INDICATOR IS NEVER/ALWAYS ON (FUSION
NON-HYBRID)

AD1 CARRY OUT THE IPC INDICATOR LAMP
TOOL
Yes
• Ignition ON. GO to AD2 .
IPC DataLogger . No
• Select the IPC charging system warning indicator INSTALL a new IPC . REFER to
(CHARGE_LMP) active command. Command the Instrument Panel Cluster (IPC) in this
charging system warning indicator on and off while section. TEST the system for normal
observing the charging system warning indicator. operation.
• Does the charging system warning indicator
illuminate when commanded on, and turn off
when commanded off?
AD2 RETRIEVE THE RECORDED DTCs FROM THE
PCM KOEO SELF-TEST
Yes
• Check for recorded PCM DTCs from the Key ON REFER to Section 414-00 .
Engine OFF (KOEO) self-test.
• Are any charging system DTCs recorded? No
GO to AD3 .
AD3 CHECK THE CHARGING SYSTEM
OPERATION
Yes
• Check the charging system operation. Refer to GO to AD4 .
Section 414-00 .
• Does the charging system operate correctly? No

AD4 RETRIEVE THE RECORDED DTCs FROM THE

IPC SELF-TEST
Yes
• Check for recorded DTCs from the IPC self-test. GO to Pinpoint Test BF .
No
INSTALL a new PCM. REFER to Refer
to the appropriate section in Group 303
for the procedure.. TEST the system for
normal operation.
Pinpoint Test AE: The Malfunction Indicator Lamp (MIL) Is Never/Always On
Normal Operation
The Malfunction Indicator Lamp (MIL) is controlled by the Instrument Panel Cluster (IPC) using data sent
from the PCM over the High Speed Controller Area Network (HS-CAN) communication bus. If the MIL
status message is missing for less than 5 seconds, the MIL remains in the last indication mode (on or off).
If the MIL status message is missing for less than 5 seconds, the MIL remains in the last indication mode (on
or off). If the MIL status message is missing for more than 5 seconds, the IPC sets DTC U0100:00 in
continuous memory and defaults the MIL on. If the MIL message is invalid for more than 5 seconds, the IPC
defaults the MIL on.
• PCM
• IPC
PINPOINT TEST AE: THE MIL IS NEVER/ALWAYS ON

AE1 CARRY OUT THE IPC WARNING LAMPS
AND CHIME ACTIVE COMMAND USING THE
SCAN TOOL
Yes
• Ignition ON. GO to AE2 .
• Select the IPC MIL (MIL_LAMP) active INSTALL a new IPC . REFER to Instrument
command. Command the MIL on and off while Panel Cluster (IPC) in this section. TEST the
observing the MIL . system for normal operation.
• Does the MIL illuminate when selected on, and
turn off when selected off?
AE2 RETRIEVE THE RECORDED DTCs FROM
PINPOINT TEST AD: THE CHARGING SYSTEM WARNING INDICATOR IS NEVER/ALWAYS5256

ON (FUSIO
• Check for recorded PCM DTCs from the Key ON Yes

Engine OFF (KOEO) self-test. DIAGNOSE all PCM DTCs first. REFER to
• Are any DTCs recorded? the Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
No
GO to AE3 .
AE3 RETRIEVE THE RECORDED DTCs FROM
THE IPC SELF-TEST
Yes
• Check for recorded DTCs from the IPC self-test. For DTC U0100:00, GO to Pinpoint Test BF .
this section.
No
INSTALL a new PCM. REFER to Refer to
the appropriate section in Group 303 for the
operation.
Pinpoint Test AF: The Powertrain Malfunction (Wrench) Warning Indicator Is Never/Always On
(Fusion Non-Hybrid)
Normal Operation
The Instrument Panel Cluster (IPC) receives the powertrain malfunction data from the PCM for the Electronic
Throttle Control (ETC) status, from the Transmission Control Module (TCM) for the transaxle status and
from the 4X4 control module for the All-Wheel Drive (AWD) status over the High Speed Controller Area
Network (HS-CAN) communication bus.
When a fault condition exists in the ETC system, the PCM provides the IPC with a message to turn the
powertrain malfunction (wrench) warning indicator on. When a fault condition exists in the transaxle, the
TCM provides the IPC with a message to turn on the powertrain malfunction (wrench) indicator. When an
AWD fault condition exists, the 4X4 control module sends the IPC a message to turn the powertrain
malfunction (wrench) warning indicator on.
If the ETC status message is missing for less than 5 seconds, the powertrain malfunction (wrench) indicator
remains in the last indication mode (on or off). If the ETC message is missing for greater than 5 seconds, the
IPC sets DTC U0100:00 and defaults the powertrain malfunction (wrench) warning indicator on.
If the transaxle status message is missing for less than 5 seconds, the powertrain malfunction (wrench)
indicator remains in the last indication mode (on or off). If the transaxle message is missing for greater than 5
seconds, the IPC sets DTC U0101:00 and defaults the powertrain malfunction (wrench) warning indicator on.
If the AWD status message is missing for less than 5 seconds, the powertrain malfunction (wrench) indicator
remains in the last indication mode (on or off). If the AWD status message is missing for greater than 5
seconds, the IPC sets DTC U0102:00 and defaults the powertrain malfunction (wrench) warning indicator on.
• ETC concern
• AWD concern
PINPOINT TEST AE: THE MIL IS NEVER/ALWAYS ON 5257

• IPC
PINPOINT TEST AF: THE POWERTRAIN MALFUNCTION (WRENCH) WARNING INDICATOR IS NEVER/ALWAYS
ON (FUSION NON-HYBRID)

AF1 CARRY OUT THE IPC INDICATOR LAMP
TOOL
Yes
• Ignition ON. GO to AF2 .
IPC DataLogger . No
• Select the IPC powertrain malfunction (wrench) INSTALL a new IPC . REFER to
warning indicator (TRANSA_LMP) active command. Instrument Panel Cluster (IPC) in this
Command the powertrain malfunction (wrench) warning section. TEST the system for normal
indicator on and off while observing the powertrain operation.
malfunction (wrench) warning indicator.
• Does the powertrain malfunction (wrench) warning
indicator illuminate when commanded on, and turn
off when commanded off?
AF2 RETRIEVE THE RECORDED DTCs FROM THE
IPC SELF-TEST
Yes
For DTC U0101:00, GO to Pinpoint

Test BG .
For DTC U0102:00, GO to Pinpoint

Test BH .

No
GO to AF3 .
PCM KOEO SELF-TEST
Yes
• Check for recorded PCM DTCs from the Key ON DIAGNOSE all PCM DTCs. REFER
Engine OFF (KOEO) self-test. to the Powertrain Control/Emissions
• Are any DTCs recorded? Diagnosis (PC/ED) manual.
No
GO to AF4 .
TCM SELF-TEST

• Check for recorded TCM DTCs from the self-test. Yes

• Are any DTCs recorded? DIAGNOSE all TCM DTCs. REFER
to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
No
DIAGNOSE all 4X4 control module
DTCs. REFER to Section 308-07A .
Pinpoint Test AG: The Cruise Control Engaged Indicator Is Never/Always On
Normal Operation
The Instrument Panel Cluster (IPC) receives the cruise control engaged signal from the PCM over the High
Speed Controller Area Network (HS-CAN) communication bus. When the cruise control is engaged, the PCM
sends a message to the IPC to illuminate the cruise control engaged indicator.
If the cruise control engaged message is missing for less than 5 seconds, the cruise control engaged indicator
remains in the last indication mode (on or off) based upon the last known good message received. If the cruise
control engaged message is missing for more than 5 seconds, the IPC sets DTC U0100:00 in continuous
memory and defaults the cruise control engaged indicator off.
• PCM
• IPC
PINPOINT TEST AG: THE CRUISE CONTROL ENGAGED INDICATOR IS NEVER/ALWAYS ON

AG1 CHECK THE CRUISE CONTROL
OPERATION
Yes
• Check the cruise control system for correct GO to AG2 .
operation.
• Does the cruise control operate correctly? No
AG2 CARRY OUT THE IPC INDICATOR LAMP
TOOL
Yes
• Ignition ON. GO to AG3 .
• Select the IPC cruise control engaged indicator INSTALL a new IPC . REFER to
(CRUISE) active command. Command the cruise Instrument Panel Cluster (IPC) in this
control engaged indicator on and off while section. TEST the system for normal
PINPOINT TEST AF: THE POWERTRAIN MALFUNCTION (WRENCH) WARNING INDICATOR

5259
IS NEVER/
observing the cruise control engaged indicator. operation.

• Does the cruise control engaged indicator
illuminate when commanded on, and turn off
when commanded off?
AG3 RETRIEVE THE RECORDED DTCs FROM
THE IPC SELF-TEST
Yes
• Check for recorded DTCs from the IPC self-test. GO to Pinpoint Test BF .
No
INSTALL a new PCM. REFER to Refer to
the appropriate section in Group 303 for the
operation.
Pinpoint Test AH: The Cruise Control On Indicator Is Never/Always On
Normal Operation
The Instrument Panel Cluster (IPC) receives the cruise control on signal from the PCM over the High Speed
Controller Area Network (HS-CAN) communication bus. When the cruise control is turned on but not
engaged, the PCM sends a message to the IPC to illuminate the cruise control on indicator.
If the cruise control on message is missing for less than 5 seconds, the cruise control on indicator remains in
the last indication mode (on or off) based upon the last known good message received. If the cruise control on
message is missing for more than 5 seconds, the IPC sets DTC U0100:00 in continuous memory and defaults
the cruise control on indicator off.
• PCM
• IPC
PINPOINT TEST AH: THE CRUISE CONTROL ON INDICATOR IS NEVER/ALWAYS ON

AH1 CHECK THE SPEED CONTROL
OPERATION
Yes
• Check the cruise control system for correct GO to AH2 .
operation.
• Does the cruise control operate correctly? No
AH2 CARRY OUT THE IPC DEALER TEST
MODE
Yes
• Ignition ON. GO to AH3 .
PINPOINT TEST AG: THE CRUISE CONTROL ENGAGED INDICATOR IS NEVER/ALWAYS ON

5260
• Enter the IPC dealer test mode.

• Scroll through the displays to TELLTALE No
TEST and monitor the cruise control on INSTALL a new IPC . REFER to Instrument
(amber) indicator. Panel Cluster (IPC) in this section. TEST the
• Does the cruise control on (amber) system for normal operation.
indicator illuminate when in the dealer
test mode and turn off when in normal
operation mode?
AH3 RETRIEVE THE RECORDED DTCs
Yes
• Check for recorded DTCs from the IPC GO to Pinpoint Test BF .
self-test.
procedure.. TEST the system for normal operation.
Pinpoint Test AI: The Grade Assist Indicator Is Never/Always On (Without Select Shift)
Normal Operation
The Instrument Panel Cluster (IPC) receives the grade assist on/off status from the PCM over the High Speed
Controller Area Network (HS-CAN) communication bus. When the grade assist function is selected off, the
PCM sends a message to the IPC to illuminate the grade assist indicator.
If the grade assist on/off message is missing for less than 5 seconds, the grade assist indicator remains in the
last state (on or off) based upon the last known good message. If the grade assist on/off message is missing for
more than 5 seconds, the IPC sets DTC U0100:00 in continuous memory and defaults the grade assist
indicator off.
• PCM
PINPOINT TEST AI: THE GRADE ASSIST INDICATOR IS NEVER/ALWAYS ON (WITHOUT SELECT SHIFT)

AI1 CHECK THE OPERATION OF THE
GRADE ASSIST FUNCTION
Yes
• Verify that the grade assist function operates GO to AI2 .
when engaged and turns off when disengaged.
• Does the grade assist function operate No
correctly? REFER to Section 307-05A .
PINPOINT TEST AH: THE CRUISE CONTROL ON INDICATOR IS NEVER/ALWAYS ON 5261

AI2 CARRY OUT THE IPC GRADE ASSIST

INDICATOR ACTIVE COMMAND USING THE
SCAN TOOL
Yes
• Ignition ON. GO to AI3 .
scan tool: IPC DataLogger . No
• Select the IPC grade assist indicator INSTALL a new IPC . REFER to Instrument
(TRAILER_LMP) active command. Panel Cluster (IPC) in this section. TEST the
Command the grade assist indicator on and off system for normal operation.
while observing the grade assist indicator.
• Does the grade assist indicator illuminate
commanded off?
AI3 RETRIEVE THE RECORDED DTCs FROM
THE IPC SELF-TEST
Yes
• Check for recorded IPC DTCs from the GO to Pinpoint Test BF .
self-test.
GO to AI4 .
AI4 RETRIEVE THE RECORDED DTCs FROM
Yes
• Check for recorded PCM DTCs from the Key REFER to the Powertrain Control/Emissions
ON Engine OFF (KOEO) self-test. Diagnosis (PC/ED) manual.
No
operation.
Pinpoint Test AJ: The PRNDL Indicator is Never/Always On
Normal Operation
The Instrument Panel Cluster (IPC) receives the transaxle range status and vehicle speed data from the PCM
over the High Speed Controller Area Network (HS-CAN) communication bus. On hybrid vehicles, the vehicle
speed data is sent to the IPC from the Transmission Control Module (TCM) over the HS-CAN
communication bus.
For all ranges other than PARK (P), the IPC displays the selected gear matching the input from the PCM.
For PARK (P), the IPC uses a park detect switch (part of the brake shift interlock) to signal the IPC that the
shift lever is fully seated in the PARK position. The IPC compares the park detect switch input with the
transaxle range status sent from the PCM. The IPC provides a reference voltage to the brake shift interlock on
the park detect input circuit. When the gearshift is in PARK (P), the brake shift indicator routes the reference
voltage to ground, pulling the circuit low. When the gearshift is moved out of PARK (P), the brake shift
PINPOINT TEST AI: THE GRADE ASSIST INDICATOR IS NEVER/ALWAYS ON (WITHOUT SELECT
5262 SHIF
interlock opens the ground sending the reference voltage high.
If the transaxle range status information is missing from the PCM for less than 5 seconds, the PRNDL
displays the last selected range based upon the last good known message. If the transaxle range status
information is missing from the PCM for 5 seconds or more, the IPC sets DTC U0100:00 and the PRNDL
display is blank. If the park detect input is open, the PARK (P) display is blank when the transaxle is in PARK
(P) but all other ranges are still displayed according to the selected range status. If the park detect input is
shorted to ground and the messaged input indicates any range other than park, the PARK (P) display is blank
once a fault is detected by the IPC (all other ranges are still displayed according to the selected range status).
tachometer, temperature gauge or odometer.
• DTC P1706:00 (High Vehicle Speed Observed in Park: No Sub-Type Information) (non-hybrid) - a
continuous memory DTC that sets if the IPC detects a short to ground on the park detect input circuit
with a Vehicle Speed Sensor (VSS) input over 16 km/h (10 mph), indicating that the vehicle is in
motion.
• DTC P1706:62 (High Vehicle Speed Observed in Park: Signal Compare Failure) (hybrid) - a
continuous memory DTC that sets if the IPC detects a short to ground on the park detect input circuit
with a Vehicle Speed Sensor (VSS) input over 16 km/h (10 mph), indicating that the vehicle is in
motion.

• Park detect switch (part of the selector lever)
• PCM
• IPC
PINPOINT TEST AJ: THE PRNDL INDICATOR IS NEVER/ALWAYS ON

AJ1 CHECK THE PRNDL DISPLAY PARK OPERATION
Yes
• Ignition ON. The system is functioning
• Shift the selector lever through the different gear positions while correctly at this time.
observing the PRNDL display.
• Place the selector lever in the PARK (P) position. No
• Observe the PRNDL display. GO to AJ2 .
• Does the PRNDL display the difnt ranges according to the
selector lever position including PARK (P)?
AJ2 RETRIEVE THE RECORD DTCs FROM THE IPC
SELF-TEST
Yes
• Check for recorded DTCs from the IPC self-test. For all DTCs, CLEAR the
• Are any DTCs recorded? DTCs. DRIVE the vehicle
above 16 km/h (10 mph) for
more than 5 seconds.

If DTC U0100:00 is present,

GO to Pinpoint Test BF .
If DTC P1706:00 (non-hybrid)

or P1706:62 (hybrid) is
present, GO to AJ5 .
No
GO to AJ3 .
AJ3 RETRIEVE AND RECORD THE DTCs FROM THE PCM
KOEO SELF-TEST
Yes
• Check for recorded PCM DTCs from the Key ON Engine OFF REFER to the Powertrain
(KOEO) self-test. Control/Emissions Diagnosis
• Are any PCM DTCs recorded? (PC/ED) manual.
No
GO to AJ4 .
AJ4 CHECK THE PARK DETECT INPUT TO THE IPC
Yes
• Ignition OFF. INSTALL a new selector
• Disconnect: Selector Lever C3233 . lever. REFER to Section
• Install a fused jumper wire between the selector lever C3233-3, 307-05A (non-hybrid) or
circuit CET52 (GN), harness side and ground. Section 307-05B (hybrid).
operation.
No
GO to AJ5 .
• Ignition ON.
• Monitor the PRNDL indicator with the jumper wire installed and
with the jumper wire removed.
• Does the PRNDL display P with the jumper wire installed
and blank with the jumper wire removed?
AJ5 CHECK THE PARK DETECT INPUT CIRCUIT FOR AN
OPEN OR SHORT TO GROUND
Yes
• Ignition OFF. INSTALL a new IPC . REFER
• Disconnect: IPC C220 . to Instrument Panel Cluster
• Measure the resistance between the IPC C220-7, circuit CET52 (IPC) in this section. TEST the
(GN), harness side and the selector lever C3233-3, circuit system for normal operation.
CET52 (GN), harness side; and between the IPC C220-7, circuit
CET52 (GN), harness side and ground. No
REPAIR the circuit. REPEAT
the self-test. CLEAR the
DTCs.
PINPOINT TEST AJ: THE PRNDL INDICATOR IS NEVER/ALWAYS ON 5264

• Is the resistance less than 5 ohms between the IPC and the
selector lever, and greater than 10,000 ohms between the IPC
and ground?
Pinpoint Test AK: The Ready To Drive Indicator Is Never/Always On (Hybrid)
Normal Operation
The purpose of the ready to drive indicator is to inform the driver that the hybrid electric drivetrain is ready to
operate. Since the engine can start and stop at different times while the vehicle is driven and operated in the
electric vehicle mode, the ready to drive indicator is used so that the customer doesn't interpret the engine
turning off as a stalled condition. The Instrument Panel Cluster (IPC) receives the electric vehicle ready to
drive on/off command from the PCM over the High Speed Controller Area Network (HS-CAN)
communication bus.
If the electric vehicle ready to drive on/off command is missing for less than 5 seconds, the ready to drive
indicator remains in the last indication mode (on or off) based upon the last known good message received. If
the electric vehicle ready to drive on/off command is missing for more than 5 seconds, the IPC sets DTC
U0100:00 in continuous memory and defaults the ready to drive indicator off.
• PCM
• IPC
PINPOINT TEST AK: THE READY TO DRIVE INDICATOR IS NEVER/ALWAYS ON (HYBRID ONLY)

AK1 CARRY OUT THE READY TO
DRIVE INDICATOR OPERATION
Yes
• Ignition ON. The system is operating correctly at this time. The ready to
• Monitor the ready to drive drive indicator illuminates whenever the ignition is turned
indicator. to the START position then returns to the RUN or ON
• Place the ignition in the START position.
position then allow the key to return
to the ON position and monitor the No
ready to drive indicator. GO to AK2 .
• Does the ready to drive indicator
remain off in the ON position and
illuminate after moving to the

START position?
AK2 CARRY OUT THE IPC DEALER
TEST MODE
Yes
• Ignition ON. GO to AK3 .
• Enter the IPC dealer test mode.
• Scroll through the displays to No
display TELLTALE TEST and INSTALL a new IPC . REFER to Instrument Panel Cluster
monitor the ready to drive indicator. (IPC) in this section. TEST the system for normal
• Does the ready to drive indicator operation.
illuminate when in the dealer test
mode and turn off when in
normal operation mode?
AK3 RETRIEVE THE RECORDED
SELF-TEST
Yes
• Check for recorded PCM DTCs REFER to the Powertrain Control/Emissions Diagnosis
from the Key ON Engine OFF (PC/ED) manual.
(KOEO) self-test.
• Are any PCM DTCs recorded? No
GO to AK4 .
AK4 RETRIEVE THE RECORDED
Yes
• Check for recorded IPC DTCs from GO to Pinpoint Test BF .
the self-test.
INSTALL a new PCM. REFER to Section 303-14D . TEST
Pinpoint Test AL: The Stop Safely Hazard Message Center Warning Indicator Is Never/Always On
(Hybrid)
Normal Operation
The stop safely hazard message center warning indicator informs the driver that a transaxle fault condition
exists or a powertrain shutdown is about to occur and service on the vehicle is required. The PCM, the
Transmission Control Module (TCM) and the Battery Pack Sensor Module (BPSM) provide the Instrument
Panel Cluster (IPC) the stop safely hazard message center indicator request over the High Speed Controller
Area Network (HS-CAN) communication bus.
If the stop safely hazard message center indicator request is missing or invalid for less than 5 seconds from
any of the source modules (PCM, TCM or BPSM ), the stop safely hazard message center warning indicator
remains in the last indication mode (on or off) based upon the last known good message received.
If the stop safely hazard message center indicator request is missing for more than 5 seconds from the PCM,
the IPC sets DTC U0100:00 in continuous memory and defaults the stop safely hazard message center
warning indicator on.
If the stop safely hazard message center indicator request is missing for more than 5 seconds from the TCM ,
PINPOINT TEST AK: THE READY TO DRIVE INDICATOR IS NEVER/ALWAYS ON (HYBRID 5266
ONLY)
If the stop safely hazard message center indicator request is missing for more than 5 seconds from the BPSM ,
• Powertrain concern
• Traction battery concern
• IPC
PINPOINT TEST AL: THE STOP SAFELY HAZARD MESSAGE CENTER WARNING INDICATOR IS NEVER/ALWAYS
ON (HYBRID ONLY)

AL1 CHECK THE MESSAGE CENTER OPERATION
Yes
• Close all doors and the luggage compartment lid. GO to AL2 .
• Ignition ON.
• Open the driver door while monitoring the message No
center displays. INSTALL a new IPC . REFER to
• Does the message center display the door ajar Instrument Panel Cluster (IPC) in this
message center warning indicator along with the section. TEST the system for normal
DRIVER DOOR AJAR text? operation.
AL2 RETRIEVE THE RECORDED DTCs FROM THE
PCM KOEO SELF-TEST
Yes
• Check for recorded PCM DTCs from the Key ON REFER to the Powertrain
Engine OFF (KOEO) self-test. Control/Emissions Diagnosis (PC/ED)
• Are any PCM DTCs recorded? manual.
No
GO to AL3 .
TCM SELF-TESTS
Yes
• Check for recorded TCM DTCs from the continuous REFER to the Powertrain
and on-demand self-tests. Control/Emissions Diagnosis (PC/ED)
• Are any TCM DTCs recorded? manual.
No
GO to AL4 .
BPSM SELF-TEST
Yes
• Check for recorded BPSM DTCs from the continuous REFER to Section 419-10 .
and on-demand self-tests.
• Are any BPSM DTCs recorded? No
GO to AL5 .


IPC SELF-TEST
Yes
• Check for recorded IPC DTCs from the self-test. REFER to DTC Charts in this section.
No
Instrument Panel Cluster (IPC) in this
operation.
Pinpoint Test AM: The Powertrain Malfunction (Wrench) Message Center Warning Indicator Is
Never/Always On (Non-Hybrid)
Normal Operation
Throttle Control (ETC) status and the transaxle status and from the 4X4 control module for the All-Wheel
Drive (AWD) status over the High Speed Controller Area Network (HS-CAN) communication bus. When a
fault condition exists in the ETC system or in the transaxle, the PCM provides the IPC with a message to turn
the powertrain malfunction (wrench) warning indicator on. When a AWD fault condition exists, the 4X4
control module sends the IPC a message to turn the powertrain malfunction (wrench) warning indicator on.
If the ETC or transaxle message is missing for greater than 5 seconds, the IPC sets DTC U0100:00 and
defaults the powertrain malfunction (wrench) warning indicator on.
If the AWD status message is missing for greater than 5 seconds, the IPC sets DTC U0102:00 and defaults the
powertrain malfunction (wrench) warning indicator on.
NOTE: If U0100:00 is set in the IPC , other symptoms may also be present such as an inoperative
speedometer, tachometer or temperature gauge.
• ETC concern
• AWD concern
• IPC
PINPOINT TEST AM: THE POWERTRAIN MALFUNCTION (WRENCH) MESSAGE CENTER WARNING INDICATOR IS
NEVER/ALWAYS ON (NON-HYBRID)

AM1 CHECK THE MESSAGE CENTER OPERATION
Yes
• Close all doors and the luggage compartment lid. GO to AM2 .
• Ignition ON.
PINPOINT TEST AL: THE STOP SAFELY HAZARD MESSAGE CENTER WARNING INDICATOR
5268IS NEVE

AM2 RETRIEVE THE RECORDED DTCs FROM THE
IPC SELF-TEST
Yes
• Are any DTCs recorded? BF .
For DTC U0102:00, GO to Pinpoint Test

BH .

No
GO to AM3 .
AM3 RETRIEVE THE RECORDED DTCs FROM THE
PCM KOEO SELF-TEST
Yes
• Check for recorded PCM DTCs from the Key ON DIAGNOSE all PCM DTCs first. REFER
No
REPAIR all 4x4 module DTCs. TEST the
Pinpoint Test AN: The Powertrain Malfunction (Wrench) Message Center Warning Indicator Is
Never/Always On (Hybrid)
Normal Operation
Throttle Control (ETC) status, the Transmission Control Module (TCM) for the transaxle status and the
Battery Pack Sensor Module (BPSM) for the traction battery status over the High Speed Controller Area
Network (HS-CAN) communication bus.
When a fault condition exists in the ETC system, the transaxle, or the traction battery system, the controlling
module (PCM, BPSM or TCM ) provides the IPC with a message to turn the powertrain malfunction (wrench)
message center warning indicator on.
If the ETC status is missing for less than 5 seconds, the powertrain malfunction (wrench) message center
warning indicator remains in the last indication mode (on or off) based upon the last known good message
received. If the ETC status is missing for greater than 5 seconds, the IPC sets DTC U0100:00 and defaults the
powertrain malfunction (wrench) message center warning indicator on.
If the transaxle status is missing for less than 5 seconds, the powertrain malfunction (wrench) message center
warning indicator remains in the last indication mode (on or off) based upon the last known good message
received. If the transaxle status is missing for greater than 5 seconds, the IPC sets DTC U0101:00 and defaults
the powertrain malfunction (wrench) message center warning indicator on.
If the traction battery status is missing for less than 5 seconds, the powertrain malfunction (wrench) message
center warning indicator remains in the last indication mode (on or off) based upon the last known good
PINPOINT TEST AM: THE POWERTRAIN MALFUNCTION (WRENCH) MESSAGE CENTER WARNING
5269 IN
message received. If the traction battery status is missing for greater than 5 seconds, the IPC sets DTC
U0111:00 and defaults the powertrain malfunction (wrench) message center warning indicator on.
NOTE: If U0100:00 is set in the IPC , other symptoms may also be present such as an inoperative
speedometer, tachometer or temperature gauge.
• ETC concern
• Traction battery concern
• IPC
PINPOINT TEST AN: THE POWERTRAIN MALFUNCTION (WRENCH) MESSAGE CENTER WARNING INDICATOR IS
NEVER/ALWAYS ON (HYBRID)

AN1 CHECK THE MESSAGE CENTER OPERATION
Yes
• Close all doors and the luggage compartment lid. GO to AN2 .
• Ignition ON.
AN2 RETRIEVE THE RECORDED DTCs FROM THE
IPC SELF-TEST
Yes
• Check for recorded DTCs from the IPC self-test. REFER to DTC Charts in this section.
No
GO to AN3 .
PCM KOEO SELF-TEST
Yes
• Check for recorded PCM DTCs from the Key ON DIAGNOSE all PCM DTCs first. REFER
No
GO to AN4 .
TCM SELF-TEST
Yes
• Check for recorded TCM DTCs from the self-test. DIAGNOSE all TCM DTCs first.
• Are any DTCs recorded? REFER to the Powertrain
manual.
No

REPAIR all BPSM DTCs. REFER to

Section 414-03 .
Pinpoint Test AO: The Engine Or Motor Over-Temperature Message Center Warning Indicator Is
Never/Always On (Hybrid)
Normal Operation
The Instrument Panel Cluster (IPC) receives the engine and motor over-temperature status from the PCM over
the High Speed Controller Area Network (HS-CAN) communication bus. If the PCM detects an engine or
motor over-temperature condition, the PCM sends a command to the IPC to turn the engine or motor
over-temperature message center warning indicator on. If the PCM determines that the engine is sufficiently
overheated to enter into the fail-safe cooling mode, the PCM sends a command to the IPC to flash the engine
or motor over-temperature message center warning indicator.
If the engine or motor over-temperature message is missing or invalid for less than 5 seconds, the engine or
motor over-temperature message center warning indicator remains in the last state (on or off) based upon the
last known good message received. If the engine over-temperature message is invalid for more than 5 seconds,
the IPC sets DTC U0401:68 in continuous memory and defaults the engine or motor over-temperature
message center warning indicator on. If the motor over-temperature message is invalid for more than 5
seconds, the IPC sets DTC U0401:68 in continuous memory and defaults the engine or motor
over-temperature message center indicator off. If the engine over-temperature message is missing for more
than 5 seconds, the IPC sets DTC U0100:00 in continuous memory and defaults the engine or motor
over-temperature message center warning indicator on.
• PCM
• IPC
PINPOINT TEST AO: THE ENGINE OR MOTOR OVER-TEMPERATURE MESSAGE CENTER WARNING INDICATOR
IS NEVER/ALWAYS ON (HYBRID)

AO1 CHECK THE MESSAGE
CENTER OPERATION
Yes
• Close all doors and the luggage GO to AO2 .
compartment lid.
• Ignition ON. No
• Open the driver door while INSTALL a new IPC . REFER to Instrument Panel Cluster
monitoring the message center (IPC) in this section. TEST the system for normal operation.
displays.
• Does the message center
display the door ajar message
center warning indicator
along with the DRIVER
DOOR AJAR text?
PINPOINT TEST AN: THE POWERTRAIN MALFUNCTION (WRENCH) MESSAGE CENTER WARNING
5271 IN
AO2 RETRIEVE THE

RECORDED DTCs FROM THE
PCM KOEO SELF-TEST
Yes
• Check for recorded PCM DTCs REFER to the Powertrain Control/Emissions Diagnosis
from the Key ON Engine OFF (PC/ED) manual.
(KOEO) self-test.
• Are any PCM DTCs No
recorded? GO to AO3 .
AO3 RETRIEVE THE
RECORDED DTCs FROM THE IPC
SELF-TEST
Yes
• Check for recorded DTCs from For DTC U0100:00, GO to Pinpoint Test BF .
the IPC self-test.
• Are any DTCs recorded? For DTC U0401:68, RETRIEVE and REPAIR all non-network
DTCs in the PCM and other modules on the network. REFER
to the Powertrain Control/Emissions Diagnosis (PC/ED)
manual and Section 419-10 for a list of all DTCs.
No
INSTALL a new PCM. REFER to Section 303-14D . TEST the
Pinpoint Test AP: The Low Fuel Message Center Warning Indicator Is Never On
Normal Operation
The low fuel message center indicator illuminates when the Distance To Empty (DTE) display is above 120
km (75 miles) (with a MyKey® programmed key) or 80 km (50 miles) (with an administrator key) to empty,
the system is operating correctly. The low fuel warning is turned on when the DTE display is 120 km (75
miles) (with a MyKey® programmed key) or 80 km (50 miles) (with an administrator key) to empty or less.
• IPC
PINPOINT TEST AP: THE LOW FUEL MESSAGE CENTER WARNING INDICATOR IS NEVER ON

AP1 CHECK THE
MESSAGE CENTER
OPERATION
Yes
• Close all doors and the GO to AP2 .
luggage compartment
lid. No
• Ignition ON. INSTALL a new IPC . REFER to Instrument Panel Cluster (IPC) in
PINPOINT TEST AO: THE ENGINE OR MOTOR OVER-TEMPERATURE MESSAGE CENTER5272

WARNING
• Open the driver door this section. TEST the system for normal operation.
while monitoring the
message cenr displays.
• Does the message
center display the door
ajar message center
warning indicator
along with the
DRIVER DOOR
AJAR text?
AP2 CHECK THE FUEL
GAUGE OPERATION
Yes
• Verify the fuel gauge is GO to AP3
operating correctly and
is not registering empty No
(E) or full (F) all the GO to Pinpoint Test B .
time.
• Does the fuel gauge
operate correctly?
AP3 CHECK THE DTE
Yes
• Scroll through the If the low fuel message center indicator is never on, INSTALL a new
information displays in IPC . REFER to Instrument Panel Cluster (IPC) in this section. TEST
the message center to the system for normal operation. If the low fuel message center
the DTE display. warning indicator is always on, the system is operating correctly at this
• Does the DTE display time.
indicate 120 km (75
miles) (with a No
MyKey® programmed If the low fuel message center warning indicator is always on,
key) or 80 km (50 INSTALL a new IPC . REFER to Instrument Panel Cluster (IPC) in
miles) (with an this section. TEST the system for normal operation. If the low fuel
administrator key) or message center warning indicator is never on, the system is operating
less? correctly at this time. The low fuel message center indicator turns on
when the fuel level is at or below 120 km (75 miles) (with a MyKey®
programmed key) or 80 km (50 miles) (with an administrator key).
Pinpoint Test AQ: The Low Oil Pressure Message Center Warning Indicator Is Never/Always On
Normal Operation
The oil pressure switch is hardwired to the Instrument Panel Cluster (IPC) and is a normally open switch.
With egine oil pressure, the oil pressure switch closes to ground and opens without oil pressure.
Non-Hybrid
The IPC provides a reference voltage to the engine oil pressure switch. When the oil pressure is within normal
ranges, the engine oil pressure switch closes to ground, pulling the reference voltage low in the IPC . With the
oil pressure switch closed, the IPC senses the low reference voltage and turns off the low oil pressure message
center warning indicator. When the engine oil pressure is low, the engine oil pressure switch opens, sending
PINPOINT TEST AP: THE LOW FUEL MESSAGE CENTER WARNING INDICATOR IS NEVER
5273
ON
the reference voltage high in the IPC . The IPC senses the high voltage and turns on the low oil pressure
message center warning indicator.
Hybrid
Due to the need to turn the internal combustion engine on and off during operation with the key in the RUN
position, the low oil pressure message center warning indicator requires two inputs. The first input is engine
rpm and the second input is oil pressure switch state. When the IPC detects engine oil pressure and receives an
rpm state over 500 rpm from the internal combustion engine, the IPC turns off the low oil pressure warning
indicator. If the oil pressure switch indicates low oil pressure and the rpm is less than 500 rpm, the low oil
pressure message center warning indicator remains off.
With the oil pressure switch closed, the IPC senses the low reference voltage and turns off the low oil pressure
warning indicator, provided engine rpm is greater than 500 rpm. When the engine oil pressure is low, the
engine oil pressure switch opens, sending the reference voltage high. The IPC senses the reference voltage has
moved high and turns the low oil pressure warning indicator on.
The IPC receives the engine rpm status from the PCM over the High Speed Controller Area Network
(HS-CAN) communication bus.
If the engine rpm status is missing or invalid for less than 5 seconds, the IPC controls the low oil pressure
message center warning based upon current oil pressure switch state and using the last known good rpm
message received. If the engine rpm status is invalid for more than 5 seconds, the IPC assumes that the rpm is
greater than 500 rpm and defaults full control of the low oil pressure message center warning indicator to the
actual oil pressure switch state. If the engine rpm status is missing for more than 5 seconds, the IPC sets DTC
U0100:00 in continuous memory and assumes that the rpm is greater than 500 rpm, defaulting full control of
the low oil pressure message center warning indicator to the actual oil pressure switch state.

• Base engine oil pressure concern
• IPC
PINPOINT TEST AQ: THE LOW OIL PRESSURE MESSAGE CENTER WARNING INDICATOR IS NEVER/ALWAYS
ON
Section 414-01 .

AQ1 CHECK THE MESSAGE CENTER
OPERATION
Yes
• Close all doors and the luggage compartment For hybrid, GO to AQ2 .
lid.
• Ignition ON. For non-hybrid, if the original symptom is the
low oil pressure warning indicator is never on,
Non-Hybrid 5274
• Open the driver door while monitoring the GO to AQ4 .

message center displays.
• Does the message center display the door For non-hybrid, if the original symptom is the
ajar message center warning indicator along low oil pressure warning indicator is always on,
with the DRIVER DOOR AJAR text? GO to AQ6 .
No
AQ2 CHECK THE TACHOMETER
Yes
• Set the message center to enlighten display If the original symptom is the low oil pressure
mode. indicator is on with the engine off and the
• Start the engine and observe the tachometer. vehicle in electric vehicle mode, GO to AQ3 .
• Is rpm present and above 500 rpm on the
tachometer? If the original symptom is the low oil pressure
warning indicator is always on, GO to AQ6 .
If the original symptom is the low oil pressure

warning indicator is never on, GO to AQ4 .
No
GO to Pinpoint Test I .
AQ3 RETRIEVE THE RECORDED DTCs
Yes
• Check for recorded DTCs from the IPC GO to Pinpoint Test BF .
self-test.
INSTALL a new IC . REFER to Instrument
AQ4 CHECK FOR A STUCK CLOSED ENGINE
OIL PRESSURE SWITCH
Yes
• Ignition OFF. INSTALL a new Engine Oil Pressure (EOP)
• Disconnect: Engine Oil Pressure Switch C103 . switch. REFER to Section 303-01C (3.5L) or
• Start the engine. Section 303-01D (hybrid). TEST the system for
• Observe the low oil pressure warning indicator. normal operation.
turn on? No
GO to AQ5 .
AQ5 CHECK OIL PRESSURE INPUT CIRCUIT
Yes
• Ignition OFF. GO to AQ9 .
• For non-hybrid, measure the resistance No
between the IPC C220-6, circuit CMC24 (GY), REPAIR the circuit. TEST the system for
harness side and ground. normal operation.
PINPOINT TEST AQ: THE LOW OIL PRESSURE MESSAGE CENTER WARNING INDICATOR
5275
IS NEVER/
• For hybrid, measure the resistance between the

IPC C220-8, circuit CMC24 (GY), harness
side and ground.

AQ6 CHECK FOR A STUCK OPEN ENGINE
OIL PRESSURE SWITCH
Yes
• Ignition OFF. REMOVE the jumper wire. GO to AQ8 .
• Disconnect: Engine Oil Pressure Switch C103 .
• Connect a fused jumper wire between the No
engine oil pressure switch, C103-1, circuit LEAVE the jumper wire connected. GO to AQ7
CMC24 (GY), harness side and ground. .

• Observe the low oil pressure warning indicator.
turn off?
AQ7 CHECK OIL PRESSURE INPUT CIRCUIT
FOR AN OPEN
Yes
• Ignition OFF. REMOVE the jumper wire. GO to AQ9 .
• Disconnect: IPC C220 . No
• For non-hybrid, measure the resistance REMOVE the jumper wire. REPAIR the circuit.
between the IPC C220-6, circuit CMC24 (GY), TEST the system for normal operation.
PINPOINT TEST AQ: THE LOW OIL PRESSURE MESSAGE CENTER WARNING INDICATOR
5276
IS NEVER/
• For hybrid, measure the resistance between the

IPC C220-8, circuit CMC24 (GY), harness
side and ground.

AQ8 CHECK THE OIL PRESSURE
Yes
• Carry out the oil pressure test. Refer to Section INSTALL a new Engine Oil Pressure (EOP)
303-00 . switch. REFER to Section 303-01C (3.5L) or
• Is the oil pressure within specification? Section 303-01D (hybrid). TEST the system for
normal operation.
No
REFER to Section 303-00 to continue diagnosis
of the low engine oil pressure concern.
AQ9 CHECK FOR CORRECT IPC OPERATION
Yes
• Disconnect the IPC connector. INSTALL a new IPC . REFER to Instrument
• Check for: Panel Cluster (IPC) in this section. TEST the
♦ damaged pins
• Connect the IPC connector and make sure it The system is operating correctly at this time.
seats correctly. The concern may have been caused by a loose or
• Operate the system and verify the concern is corroded connector.
still present.
Pinpoint Test AR: The Door/hood Ajar Message Center Warning Indicator Is Never/Always On
Normal Operation
The Instrument Panel Cluster (IPC) receives the door ajar status for the LH front door, RH front door, LH rear
door, the RH rear door, the hood and the decklid (non-hybrid only) ajar switch status from the Smart Junction
Box (SJB) over the Medium Speed Controller Area Network (MS-CAN) communication bus. When the IPC

receives a message from the SJB that one or more doors, the hood or the decklid (non-hybrid only) are open
or ajar, the IPC turns on the door/hood ajar message center warning indicator.
If the door/hood ajar status message is missing for less than 5 seconds, the door/hood ajar message center
warning indicator remains in the last state (on or off) based upon the last known good message received for
each of the door ajar states. If the door/hood ajar status message is missing for greater than 5 seconds, the IPC
sets DTC U0140:00 and defaults the door/hood ajar message center warning indicator on.
(TPMS).
• Interior lighting concern

• SJB
• IPC
PINPOINT TEST AR: THE DOOR/HOOD AJAR MESSAGE CENTER WARNING INDICATOR IS NEVER/ALWAYS ON

AR1 CHECK THE INTERIOR LIGHTING
OPERATION
Yes
• Open and close each door while monitoring the GO to AR2 .
courtesy lamps.
• Do the courtesy lamps operate correctly with No
each door? REFER to Section 417-02 .
AR2 CHECK THE HOOD AJAR SWITCH
STATUS PID
Yes
• Ignition ON. GO to AR3 .
tool: SJB DataLogger. No
• Select the SJB hood ajar switch PID REFER to Section 419-01A to diagnose the
(HOOD_SW). Monitor the PID with the hood hood ajar switch circuit.
closed and open.
• Does the PID agree with the status of the
hood?
AR3 CHECK THE MESSAGE CENTER
OPERATION
Yes
• Ignition OFF. GO to AR4 .
• Disconnect: PCM C175b .
• Ignition ON. No
• Monitor the message center display area with the INSTALL a new IPC . REFER to Instrument
PCM disconnected. Panel Cluster (IPC) in this section. TEST the
• Does the message center display the system for normal operation.
powertrain malfunction (wrench) message
center warning indicator?
PINPOINT TEST AR: THE DOOR/HOOD AJAR MESSAGE CENTER WARNING INDICATOR IS
5278
NEVER/A
AR4 RETRIEVE THE RECORDED DTCs FROM

Yes
• Check for recorded IPC DTCs from the GO to Pinpoint Test BM .
continuous self-test.
GO to AR5 .
AR5 RETRIEVE THE RECORDED DTCs FROM
THE SJB SELF-TEST
Yes
• Check for recorded DTCs from the SJB self-test. REFER to Section 419-10 for correct
• Are any SJB DTCs recorded? navigation of the DTC.
No
operation.
Pinpoint Test AS: The Charging System Message Center Warning Indicator Is Never/Always On
Normal Operation
The charging system indicator is controlled by the Instrument Panel Cluster (IPC) based upon data received
from the PCM (non-hybrid) or the DC to DC Converter Control Module (DC/DC) (hybrid) over the High
Speed Controller Area Network (HS-CAN) communication bus.
If the charging system message is missing for less than 5 seconds, the charging system message center
warning indicator remains in the last state (on or off) based upon the last known good message received. If the
charging system message is missing for more than 5 seconds, the IPC sets DTC U0100:00 (non-hybrid) or
DTC U0298:00 (hybrid) in continuous memory and defaults the charging system warning indicator on.

• DC/DC (hybrid)
• IPC
PINPOINT TEST AS: THE CHARGING SYSTEM MESSAGE CENTER WARNING INDICATOR IS NEVER/ALWAYS ON

AS1 CHECK THE MESSAGE CENTER
OPERATION
Yes
• Close all doors and the luggage For non-hybrid, GO to AS2 .
compartment lid.
• Ignition ON. For hybrid, GO to AS4 .

• Open the driver door while

monitoring the message center No
displays. INSTALL a new IPC . REFER to Instrument Panel
• Does the message center display the Cluster (IPC) in this section. TEST the system for normal
door ajar message center warning operation.
indicator along with the DRIVER
DOOR AJAR text?
AS2 RETRIEVE THE RECORDED
SELF-TEST
Yes
• Check for recorded PCM DTCs from REFER to Section 414-00 .
the Key ON Engine OFF (KOEO)
self-test. No
• Are any charging system DTCs GO to AS3 .
recorded?
AS3 CHECK THE CHARGING SYSTEM
OPERATION
Yes
• Check the charging system operation. GO to AS4 .
• Does the charging system operate No
correctly? REFER to Section 414-00 .
AS4 RETRIEVE THE RECORDED
Yes
• Check for recorded DTCs from the For DTC U0100:00, GO to Pinpoint Test BF .
IPC self-test.
• Are any DTCs recorded? For DTC U0298:00, GO to Pinpoint Test BW .
REFER to DTC Charts in this section.
No
If the charging system warning indicator is never on, the
system is operating correctly at this time.
If the charging system warning indicator is always on for

non-hybrid vehicles, INSTALL a new PCM. REFER to
Section 303-14C . TEST the system for normal
operation.
If the charging system warning indicator is always on for

hybrid vehicles, REFER to Section 414-05 to diagnose
the DC/DC charging system. TEST the system for
normal operation.
Pinpoint Test AT: The Trunk Ajar Message Center Warning Indicator Is Never/Always On (Hybrid)
Refer to Wiring Diagrams Cell 113 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Luggage Compartment for
PINPOINT TEST AS: THE CHARGING SYSTEM MESSAGE CENTER WARNING INDICATOR5280
IS NEVER/A
Normal Operation
The Instrument Panel Cluster (IPC) receives the trunk ajar status from the Smart Junction Box (SJB) over the
Medium Speed Controller Area Network (MS-CAN) communication bus. The luggage compartment lid ajar
switch (part of the luggage compartment lid latch) is hardwired to the SJB through the decklid ajar input
circuit. The luggage compartment lid ajar switch is grounded through an external ground circuit. When the
luggage compartment lid is ajar, the luggage compartment lid latch removes the ground to the luggage
compartment lid ajar switch input. When the luggage compartment lid is closed, the luggage compartment lid
release grounds the luggage compartment lid ajar switch.
When the SJB detects an open on the decklid ajar input circuit, the SJB sends a message to the IPC to turn on
the trunk ajar message center indicator.
If the decklid ajar status message is missing for less than 5 seconds, the trunk ajar message center warning
indicator remains in the last state (on or off) based upon the last known good message received. If the decklid
ajar status message is missing for greater than 5 seconds, the IPC sets DTC U0140:00 and defaults the decklid
ajar message center warning indicator on.
(TPMS).

• Luggage compartment lid ajar switch (part of the luggage compartment lid latch)
• SJB
• IPC
PINPOINT TEST AT: THE TRUNK AJAR MESSAGE CENTER WARNING INDICATOR IS NEVER/ALWAYS ON
(HYBRID)
Section 414-01 .

AT1 CHECK THE MESSAGE CENTER OPERATION
Yes
• Close all doors, hood and luggage compartment lid. GO to AT2 .
• Ignition ON.
• Open the driver door while monitoring the message center No
displays. INSTALL a new IPC . REFER to
• Does the door ajar message center warning indicator Instrument Panel Cluster (IPC) in this
turn on? section. TEST the system for normal
operation.
AT2 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Yes
• Retrieve the recorded DTCs from the IPC self-test. GO to Pinpoint Test BM .


No
GO to AT3 .
AT3 CHECK THE LUGGAGE COMPARTMENT LID
LATCH OPERATION
Yes
• Press the luggage compartment lid release switch. GO to AT4 .
• Does the luggage compartment lid release function
operate? No
AT4 CHECK THE LUGGAGE COMPARTMENT LID
AJAR SWITCH
Yes
• Ignition OFF. INSTALL a new luggage
• Disconnect: Luggage Compartment Lid Latch C429 . compartment lid latch. REFER to
• Ignition ON. Section 501-14 . TEST the system for
• Measure the voltage between the luggage compartment normal operation.
lid latch C429-1, circuit CPL58 (GY/OG), harness side
and ground. No
GO to AT5 .
• Is the voltage greater then 10 volts?

AT5 CHECK THE DECKLID AJAR INPUT CIRCUIT
Yes
• Ignition OFF. GO to AT6 .
• Disconnect: SJB C2280c .
• Measure the resistance between the SJB C2280c-16, No
circuit CPL58 (GY/OG), harness side and ground. REPAIR the circuit. TEST the system

AT6 CHECK THE DECKLID AJAR INPUT CIRCUIT
FOR AN OPEN
PINPOINT TEST AT: THE TRUNK AJAR MESSAGE CENTER WARNING INDICATOR IS NEVER/ALWAYS
5282
• Disconnect: Negative Battery Cable . Yes

• Connect a fused jumper wire between the luggage GO to AT7 .
compartment lid latch C429-1, circuit CPL58 (GY/OG),
REPAIR the circuit. TEST the system
• Measure the resistance between the SJB C2280c-16,

circuit CPL58 (GY/OG), harness side and ground.

AT7 CHECK FOR CORRECT SJB OPERATION
Yes
♦ damaged pins
Pinpoint Test AU: The Message Center Is Not Operating Correctly
Normal Operation
The message center shares the Instrument Panel Cluster (IPC) RUN/START voltage, keep alive memory
voltage and the IPC logic ground to operate. The message center functionality is controlled through the
message center switch and is hardwired to the IPC through separate signal and return circuits.
• DTC B1A82:11 (External Trip Switch: Circuit Short to Ground) - a continuous DTC that sets in the
IPC if the IPC detects a short to ground on the message center signal circuit.
• DTC B1A82:13 (External Trip Switch: Circuit Open) - a continuous DTC that sets in the IPC if the
IPC detects an open on the message center signal circuit.


• Clockspring
• Front Controls Interface Module (FCIM) (MKZ only)
• Steering wheel switch (part of the cruise control switch)
• IPC
PINPOINT TEST AU: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY

AU1 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Yes
• Check for recorded DTCs from the IPC self-test. GO to AU6 .
• Is DTC B1A82:11 or DTC B1A82:13 recorded?
No
GO to AU2 .
AU2 CHECK THE IPC ODOMETER DISPLAY
Yes
• Ignition ON. For non-hybrid, GO to AU3 .
• Observe the odometer display in the message center.
• Is the odometer displayed? For hybrid, GO to AU4 .
No
If the display is blank, PRESS the
INFO button to see if the message
center was previously set to the
blank display.
If the display remains blank, GO to

Pinpoint Test A .
AU3 CARRY OUT THE IPC DEALER TEST MODE ALL
SEGMENTS DISPLAY
Yes
• NOTE: The all segments display is the second button press GO to AU4 .
after entering the dealer test mode immediately following
the gauge test. No
• Enter the IPC dealer test mode. Scroll through the displays INSTALL a new IPC . REFER to
until the message center displays all the segments. Instrument Panel Cluster (IPC) in
• Does the message center display all the illuminate this section. TEST the system for
segments? normal operation.
AU4 CHECK FOR VOLTAGE FROM THE IPC
PINPOINT TEST AU: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY 5284

• Disconnect: FCIM C2402 (MKZ) . GO to AU5 .
• Disconnect: LH Steering Wheel Switch C2998 (Fusion).
• Ignition ON. No
• For MKZ, measure the voltage between the FCIM C2402-3, GO to AU18 .
circuit CMC29 (GN/VT), harness side and the FCIM
C2402-4, circuit RMC27 (WH/BN), harness side.
• For Fusion, measure the voltage between the LH steering

wheel switch C2998-7, circuit CMC29 (GN/VT), harness
side and the LH steering wheel switch C2998-10, circuit
RMC27 (WH/BN), harness side.
• Is the voltage approximately 5 volts?

AU5 CHECK FOR THE MESSAGE CENTER SWITCH
OPERATION
Yes
• Ignition OFF. GO to AU18 .
• Connect: FCIM C2402 (MKZ) . No
• Connect: LH Steering Wheel Switch C2998 (Fusion) . For MKZ, GO to AU17 .
• For non-hybrid, measure the resistance between the IPC
C220-16, circuit CMC29 (GN/VT), harness side and the For Fusion, INSTALL a new cruise
IPC C220-3, circuit RMC27 (WH/BN), harness side while control switch. REFER to Section
pressing the message center buttons according to the 419-03 . TEST the system for
following table. normal operation.
Message Center Button Press Resistance

No button press 7,200-7,800 ohms
INFO 123-133 ohms
SETUP 1,381-1,496 ohms
RESET 599-649 ohms

C220-24, circuit CMC29 (GN/VT), harness side and the
IPC C220-11, circuit RMC27 (WH/BN), harness side while
pressing the message center buttons according to the
following table.
Message Center Button Press Resistance

No button press 7,200-7,800 ohms
INFO 123-133 ohms
SETUP 1,381-1,496 ohms
RESET 599-649 ohms
• Is the resistance within the specifications for all

positions?
AU6 CHECK THE MESSAGE CENTER SIGNAL AND
RETURN CIRCUITS FOR A SHORT TO VOLTAGE
Yes
• Disconnect: IPC C220 . CLEAR the DTCs. REPEAT the
• For non-hybrid, measure the voltage between the IPC
C220-16, circuit CMC29 (GN/VT), harness side and No
ground; and between the IPC C220-3, circuit RMC27 GO to AU7 .
(WH/BN), harness side and ground.
• For hybrid, measure the voltage between the IPC C220-24,

circuit CMC29 (GN/VT), harness side and ground; and
between the IPC C220-11, circuit RMC27 (WH/BN),

AU7 CHECK THE MESSAGE CENTER SIGNAL CIRCUIT
Yes
• For non-hybrid, measure the resistance between the IPC
C220-16, circuit CMC29 (GN/VT), harness side and No
ground. GO to AU9 .

C220-24, circuit CMC29 (GN/VT), harness side and
ground.

AU8 CHECK THE MESSAGE CENTER SIGNAL AND

• For non-hybrid, measure the resistance between the IPC GO to AU12 .
IPC C220-3, circuit RMC27 (WH/BN), harness side. No
REPAIR the circuit. Clear the

IPC C220-11, circuit RMC27 (WH/BN), harness side.

AU9 CHECK THE MESSAGE CENTER SWITCH FOR A
SHORT TO GROUND
Yes
• Disconnect: FCIM C2402 (MKZ). For Fusion, INSTALL a new cruise
• Disconnect: LH Steering Wheel Switch C2998 (Fusion). control switch. REFER to Section
• For non-hybrid, measure the resistance between the IPC 419-03 . CLEAR the DTCs.
C220-16, circuit CMC29 (GN/VT), harness side and REPEAT the self-test. For MKZ,
ground. GO to AU17 .
No
For Fusion, GO to AU10 .
For MKZ, REPAIR the circuit in

question. CLEAR the DTCs.

ground.

AU10 CHECK THE STEERING WHEEL HARNESS FOR A
SHORT TO GROUND
Yes
• Remove the driver air bag. Refer to Section 501-20B . REPAIR or INSTALL a new
• Disconnect: Clockspring C218b . steering wheel switch harness.
• For non-hybrid, measure the resistance between the IPC CLEAR the DTCs. REPEAT the
C220-16, circuit CMC29 (GN/VT), harness side and self-test.
ground.
No
GO to AU11 .

ground.

AU11 CHECK THE CLOCKSPRING FOR A SHORT TO
GROUND
Yes
• Disconnect: Clockspring C218a . INSTALL a new clockspring.
• For non-hybrid, measure the resistance between the IPC REFER to Section 501-20B .
C220-16, circuit CMC29 (GN/VT), harness side and CLEAR the DTCs. REPEAT the
ground. self-test.
No
REPAIR circuit CMC29 (GN/VT)
for a short to ground. INSTALL the
driver air bag. REFER to Section
501-20B . CLEAR the DTCs.

ground.

AU12 CHECK THE MESSAGE CENTER SIGNAL CIRCUIT
FOR AN OPEN
Yes
• Disconnect: FCIM C2402 (MKZ) . GO to AU13 .
• Disconnect: Clockspring C218a (Fusion) .
• For MKZ, measure the resistance between the IPC C220-16 No
(non-hybrid) or C220-24 (hybrid), circuit CMC29 (GN/VT), REPAIR the circuit. CLEAR the
harness side and the FCIM C2402-3, circuit CMC29 DTCs. REPEAT the self-test.
• For Fusion, measure the resistance between the IPC

C220-24 (non-hybrid) or C220-24 (hybrid), circuit CMC29
(GN/VT), harness side and the clockspring C218a-3, circuit
CMC29 (GN/VT), harness side.
AU13 CHECK THE MESSAGE CENTER RETURN

CIRCUIT FOR AN OPEN
Yes
• For MKZ, measure the resistance between the IPC C220-3 For MKZ, GO to AU17 . REFER
(non-hybrid) or C220-11 (hybrid), circuit RMC27 to Section 415-00 . CLEAR the
(WH/BN), harness side and the FCIM C2402-4, circuit DTCs. REPEAT the self-test.
RMC27 (WH/BN), harness side.
For Fusion, GO to AU14 .
No
REPAIR the circuit. CLEAR the
• For Fusion, measure the resistance between the C220-3

(non-hybrid) or C220-11 (hybrid), circuit RMC27
(WH/BN), harness side and the clockspring C218a-11,
circuit RMC27 (WH/BN), harness side.

AU14 CHECK THE MESSAGE CENTER SWITCH SIGNAL
CIRCUIT FOR AN OPEN AT THE LH STEERING WHEEL
SWITCH
Yes
• Disconnect: LH Steering Wheel Switch C2998 . GO to AU15 .
• Measure the resistance between the lower clockspring
C218a pin 3, component side and the LH steering wheel No
switch C2998-7, circuit CMC29 (GN/VT), harness side. GO to AU16 .

AU15 CHECK THE MESSAGE CENTER SWITCH
RETURN CIRCUIT FOR AN OPEN AT THE LH STEERING
WHEEL SWITCH
• Measure the resistance between the lower clockspring Yes

C218a pin 11, component side and the LH steering wheel INSTALL a new cruise control
switch C2998-10, circuit RMC27 (WH/BN), harness side. switch. REFER to Section 419-03 .
self-test.
No
GO to AU16 .

AU16 CHECK THE CLOCKSPRING FOR AN OPEN
Yes
• Remove the driver air bag. Refer to Section 501-20B . REPAIR or INSTALL a new
• Disconnect: Clockspring C218b . steering wheel switch harness.
• Measure the resistance between the lower clockspring CLEAR the DTCs. REPEAT the
C218a pin 3, circuit component side and the upper self-test.
clockspring C218b pin 6, component side; and between the
lower clockspring C218a pin 11, component side and the No
upper clockspring C218b pin 12, component side. INSTALL a new clockspring.
REFER to Section 501-20B .
self-test.

AU17 CHECK FOR CORRECT FCIM OPERATION
Yes
• Disconnect the FCIM connector. INSTALL a new FCIM . REFER to
♦ damaged pins
• Connect the FCIM connector and make sure it seats The system is operating correctly at
AU18 CHECK FOR CORRECT IPC OPERATION
Yes
• Check for: Instrument Panel Cluster (IPC) in
♦ corrosion this section. TEST the system for
♦ damaged pins normal operation.
♦ pushed-out pins
• Connect the IPC connector and make sure it seats correctly. No
• Operate the system and verify the concern is still present. The system is operating correctly at
• Is the concern still present? this time. The concern may have
been caused by a loose or corroded
Pinpoint Test AV: The CHECK FUEL FILL INLET Message Is Inoperative/Always On
Normal Operation
The PCM monitors the fuel tank evaporative emission system for significant leaks that occur following
refueling of the vehicle. Once the PCM detects a fuel vapor leak, the PCM sends the Instrument Panel Cluster
(IPC) a message over the High Speed Controller Area Network (HS-CAN) communication bus to turn on the
CHECK FUEL FILL INLET message. DTC P0457 sets in the PCM following a successful cruise test, which
is initiated when the vehicle is driven at a steady speed above 64 km/h (40 mph) for a duration of
approximately 4-5 minutes. If the PCM is unable to successfully run the cruise test, the IPC does not receive
the message from the PCM and the CHECK FUEL FILL INLET message remains off.
If the IPC does not receive the fuel cap off data from the PCM for 5 seconds or less, the IPC defaults the
CHECK FUEL FILL INLET message to the last setting, based upon the last known good data message. If the
IPC does not receive the fuel cap off data from the PCM for more than 5 seconds or if the data received is
deemed invalid, the IPC sets DTC U0100:00 in continuous memory and defaults the CHECK FUEL FILL
INLET message off.
temperature gauge (except hybrid) or odometer.
• DTC P0457 (Evaporative Emission System Leak Detected) (fuel cap loose/off) - sets in the PCM if a
fuel tank pressure change greater than -23.7 kPa (-7 in-Hg) of vacuum within 30 seconds after
refueling occurs, or there is an excessive purge (fuel vapor) flow of greater than 454 g (1.0 lb) per
minute.
• Evaporative emissions concern

• PCM
• IPC
PINPOINT TEST AV: THE CHECK FUEL FILL INLET MESSAGE IS INOPERATIVE/ALWAYS ON

AV1 CHECK THE
MESSAGE CENTER
DISPLAY OPERATION
Yes
• Close all doors and GO to AV2 .
the luggage
compartment lid. No
• Ignition ON. INSTALL a new IPC . REFER to Instrument Panel Cluster (IPC) in this
• Open the driver section. TEST the system for normal operation.
door and observe

the message center.

• Does the message
center display
DRIVER DOOR
AJAR?
AV2 RETRIEVE THE
RECORDED DTCs
FROM THE PCM KOEO
SELF-TEST
Yes
• Check for recorded If the CHECK FUEL FILL INLET message is displayed, REFER to the
PCM DTCs from Powertrain Control/Emissions Diagnosis (PC/ED) manual.
the Key ON Engine
OFF (KOEO) If the CHECK FUEL FILL INLET message is not displayed, GO to AV3 .
self-test.
• Is DTC P0457 No
recorded? If the CHECK FUEL FILL INLET message is always displayed, INSTALL
a new IPC . REFER to Instrument Panel Cluster (IPC) in this section. TEST
If the CHECK FUEL FILL INLET message is not displayed, the system is
operating normally at this time. If the capless fuel fill inlet was open and the
CHECK FUEL FILL INLET message did not turn on, driving conditions
may not have allowed for the PCM to run the cruise test and message the
IPC to turn on the CHECK FUEL FILL INLET message.
AV3 RETRIEVE THE
RECORDED DTCs
FROM THE IPC
SELF-TEST
Yes
• Check for recorded GO to Pinpoint Test BF .
IPC DTCs from the
self-test. No
• Is DTC U0100 INSTALL a new PCM. REFER to Refer to the appropriate section in Group
recorded? 303 for the procedure.. TEST the system for normal operation.
Pinpoint Test AW: The SERVICE STEERING Message Is Inoperative/Always On
Normal Operation
The Instrument Panel Cluster (IPC) receives the Electronic Power Assist Steering (EPAS) system status from
the Power Steering Control Module (PSCM) (part of the steering gear) through the High Speed Controller
Area Network (HS-CAN) communication bus. When the PSCM detects a fault in the EPAS system, the
PSCM sends a message to the IPC to turn on the SERVICE STEERING message in the message center.
• EPAS system concern

• PSCM (part of the steering gear)
• IPC
PINPOINT TEST AV: THE CHECK FUEL FILL INLET MESSAGE IS INOPERATIVE/ALWAYS ON
5294
PINPOINT TEST AW: THE SERVICE STEERING MESSAGE IS INOPERATIVE/ALWAYS ON

AW1 CHECK THE MESSAGE CENTER
DISPLAY OPERATION
Yes
• Close all doors and the luggage GO to AW2 .
compartment lid.
• Ignition ON. No
• Open the driver door and observe the INSTALL a new IPC . REFER to Instrument Panel
message center. Cluster (IPC) in this section. TEST the system for
• Does the message center display normal operation.
DRIVER DOOR AJAR?
AW2 RETRIEVE THE RECORDED DTCs
Yes
• Check for recorded DTCs from the IPC GO to Pinpoint Test BL .
self-test.
GO to AW3 .
AW3 RETRIEVE THE RECORDED DTCs
FROM THE PSCM SELF-TEST
Yes
• Check for recorded DTCs from the PSCM REFER to Section 211-00A .
self-test.
INSTALL a new steering gear. REFER to Section
Pinpoint Test AX: The TRUNK AJAR Message Is Inoperative/Always On
Refer to Wiring Diagrams Cell 113 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Luggage Compartment for
Normal Operation
The Instrument Panel Cluster (IPC) receives the trunk ajar status from the Smart Junction Box (SJB) over the
Medium Speed Controller Area Network (MS-CAN) communication bus. The luggage compartment lid ajar
switch (part of the luggage compartment lid latch) is hardwired to the SJB through the trunk ajar input circuit.
The luggage compartment lid ajar switch is grounded externally. When the luggage compartment lid is ajar,
the luggage compartment lid latch removes the ground to the luggage compartment lid ajar switch input to the
SJB . When the luggage compartment lid is closed, the luggage compartment lid release grounds the luggage
compartment lid ajar switch.
When the SJB detects an open on the trunk ajar input circuit, the SJB sends a message to the IPC to turn on
the TRUNK AJAR message in the message center.

• Luggage compartment lid ajar switch (part of the luggage compartment lid latch)
• SJB
PINPOINT TEST AW: THE SERVICE STEERING MESSAGE IS INOPERATIVE/ALWAYS ON 5295

• IPC
PINPOINT TEST AX: THE TRUNK AJAR MESSAGE IS INOPERATIVE/ALWAYS ON
Section 414-01 .

AX1 CHECK THE MESSAGE CENTER OPERATION
Yes
• Close all doors, hood and luggage compartment lid. GO to AX2 .
• Ignition ON.
• Open the driver door while monitoring the message center No
displays. INSTALL a new IPC . REFER to
• Does the message center display DRIVER DOOR Instrument Panel Cluster (IPC) in this
AJAR? section. TEST the system for normal
operation.
AX2 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Yes
• Retrieve the recorded DTCs from the IPC self-test. GO to Pinpoint Test BM .
No
GO to AX3 .
AX3 CHECK THE LUGGAGE COMPARTMENT LID
LATCH OPERATION
Yes
• Press the luggage compartment lid release switch on the GO to AX4 .
instrument panel.
• Does the luggage compartment lid release function No
operate? REFER to Section 501-14 .
AX4 CHECK THE LUGGAGE COMPARTMENT LID
AJAR SWITCH
Yes
• Ignition OFF. INSTALL a new luggage
• Disconnect: Luggage Compartment Lid Latch C429 . compartment lid latch. REFER to
• Ignition ON. Section 501-14 . TEST the system for
• Measure the voltage between the luggage compartment normal operation.
lid latch C429-1, circuit CPL58 (GY/OG), harness side
and ground. No
GO to AX5 .

• Is the voltage greater then 10 volts?

AX5 CHECK THE TRUNK AJAR INPUT CIRCUIT FOR
A SHORT TO GROUND
Yes
• Ignition OFF. GO to AX6 .
• Disconnect: SJB C2280c .
• Measure the resistance between the SJB C2280c-16, No
circuit CPL58 (GY/OG), harness side and ground. REPAIR the circuit. TEST the system

AX6 CHECK THE TRUNK AJAR INPUT CIRCUIT FOR
AN OPEN
Yes
• Disconnect: Negative Battery Cable . GO to AX7 .
• Connect a fused jumper wire between the luggage
compartment lid latch C429-1, circuit CPL58 (GY/OG), No
harness side and ground. REPAIR the circuit. TEST the system
• Measure the resistance between the SJB C2280c-16,

circuit CPL58 (GY/OG), harness side and ground.
PINPOINT TEST AX: THE TRUNK AJAR MESSAGE IS INOPERATIVE/ALWAYS ON 5297


AX7 CHECK FOR CORRECT SJB OPERATION
Yes
♦ damaged pins
Pinpoint Test AY: The Chime Sounds When The Driver Door Is Ajar (No Key In Ignition And
Headlamps Off)
Normal Operation
The Instrument Panel Cluster (IPC) receives the key-in-ignition warning status from the Smart Junction Box
(SJB) over the Medium Speed Controller Area Network (MS-CAN) communication bus.
The key-in-ignition warning switch (part of the ignition switch) is hardwired to the SJB through the
key-in-ignition input circuit. When the key is inserted into the ignition lock cylinder, the key-in-ignition
switch closes and supplies voltage to the SJB .
The SJB monitors the door ajar input from the LH front door and the key-in-ignition switch status. When the
SJB detects a key-in-ignition voltage and the LH front door is open or ajar, the SJB sends the IPC a chime
request message to sound the key-in-ignition warning chime.
• DTC B1352 (Ignition Key-In Circuit Failure) - an on-demand DTC that sets in the SJB if the SJB
detects a short to voltage on the key-in-ignition switch input circuit or if the SJB detects ignition
START, RUN/START or RUN/ACC inputs without the key-in-ignition input.

• Key-in-ignition warning switch (part of the ignition switch)
• SJB
PINPOINT TEST AY: THE CHIME SOUNDS WHEN THE DRIVER DOOR IS AJAR (NO KEY IN IGNITION AND
HEADLAMPS OFF)

AY1 CHECK THE IPC ILLUMINATION

• Verify the IPC is not illuminated with the headlamp switch Yes
off. GO to AY2 .
• Does the IPC illumination operate correctly?
No
AY2 RETRIEVE THE RECORDED DTCs FROM THE SJB
SELF-TEST
Yes
• Check for recorded DTCs from the SJB self-test. GO to AY3 .
• Is DTC B1352 present?
No
GO to AY4 .
AY3 CHECK THE SJB IGNITION INPUT PIDs
Yes
• Ignition ON. INSTALL a new SJB . REFER
• Enter the following diagnostic mode on the scan tool: SJB to Section 419-10 . TEST the
DataLogger . system for normal operation.
• Select and monitor the SJB PIDs ignition ACC
(IGN_A_ECU), ignition OFF (IGN_O_ECU), ignition RUN No
(IGN_R_ECU), and ignition START (IGN_S_ECU) while REFER to Section 211-05 to
cycling the ignition from ACC, OFF, RUN and START. diagnose the ignition outputs to
• Do the SJB PIDs match the ignition mode? the SJB .
AY4 CHECK THE KEY-IN-IGNITION INPUT CIRCUIT FOR
VOLTAGE
Yes
• Ignition OFF. GO to AY5 .
• Disconnect: SJB C2280b .
• Measure the voltage between the SJB C2280b-35, circuit No
CDC30 (BU/GY), harness side and ground. GO to AY6 .

AY5 CHECK THE KEY-IN-IGNITION INPUT CIRCUIT FOR
A SHORT TO VOLTAGE
Yes
• Disconnect: Ignition Switch C250 . REPAIR the circuit. TEST the
• Measure the voltage between the SJB C2280b-35, circuit system for normal operation.
CDC30 (BU/GY), harness side and ground.
No
operation.
PINPOINT TEST AY: THE CHIME SOUNDS WHEN THE DRIVER DOOR IS AJAR (NO KEY IN5299
IGNITION A

AY6 CHECK FOR CORRECT SJB OPERATION
Yes
♦ damaged pins
• Connect all the SJB connectors and make sure they seat The system is operating correctly
correctly. at this time. The concern may
• Operate the system and verify the concern is still present. have been caused by a loose or
Pinpoint Test AZ: The Key-In-Ignition Warning Chime Is Inoperative
Normal Operation
The Instrument Panel Cluster (IPC) receives the key-in-ignition warning status from the Smart Junction Box
(SJB) over the Medium Speed Controller Area Network (MS-CAN) communication bus.
The key-in-ignition warning switch (part of the ignition switch) is hardwired to the SJB through the
key-in-ignition input circuit. When the key is inserted into the ignition lock cylinder, the key-in-ignition
switch closes and supplies voltage to the SJB .
The SJB monitors the door ajar input from the LH front door and the key-in-ignition switch status. When the
SJB detects a key-in-ignition voltage and the LH front door is open or ajar, the SJB sends the IPC a chime
request message to sound the key-in-ignition warning chime.
• DTC B1352 (Ignition Key-In Circuit Failure) - an on-demand DTC that sets in the SJB if the SJB
detects an open on the key-in-ignition switch input circuit or if the SJB detects ignition START,
RUN/START or RUN/ACC inputs without the key-in-ignition input.

• Key-in-ignition switch (part of the ignition switch)
• SJB
• IPC

PINPOINT TEST AZ: THE KEY-IN-IGNITION WARNING CHIME IS INOPERATIVE

AZ1 CHECK THE SAFETBELT
WARNING CHIME OPERATION
Yes
• Ignition OFF. GO to AZ2 .
• Ignition ON.
• Monitor the safety belt warning No
chime when the ignition is INSTALL a new IPC . REFER to Instrument Panel Cluster
transitioned from OFF to RUN (IPC) in this section. TEST the system for normal operation.
for 6 seconds.
• Does the safety belt warning
chime operate for
approximately 6 seconds?
AZ2 CHECK THE MESSAGE
CENTER OPERATION
Yes
• Close all doors, hood and GO to AZ3 .
luggage compartment lid.
• Ignition ON. No
• Open the driver door while GO to Pinpoint Test AA to diagnose the door/hood ajar
monitoring the message center warning indicator (non-hybrid) or GO to Pinpoint Test AR to
displays. diagnose the door ajar message center warning indicator (MKZ
• Does the message center or hybrid).
display DRIVER DOOR
AJAR?
AZ3 RETRIEVE THE RECORDED
DTCs FROM THE SJB SELF-TEST
Yes
• Check for recorded DTCs from GO to AZ4 .
the SJB self-test.
• Is DTC B1352 present? No
INSTALL a new SJB . REFER to Section 419-10 . TEST the
AZ4 CHECK THE IGNITION
SWITCH
Yes
• Ignition OFF. REPAIR circuit CDC30 (BU/GY) for an open. CLEAR the
• Disconnect: Ignition Switch DTCs. REPEAT the self-test.
C250 .
• Carry out the ignition switch No
component test. INSTALL a new ignition switch. REFER to Section 211-05 .
Refer to Wiring Diagrams Cell
149 ( Fusion/MKZ , Fusion
Hybrid/MKZ Hybrid ) for
component testing.
• Is the ignition switch OK?
Pinpoint Test BA: The Headlamps On Warning Chime Is Inoperative
PINPOINT TEST AZ: THE KEY-IN-IGNITION WARNING CHIME IS INOPERATIVE 5301

Normal Operation
The Smart Junction Box (SJB) receives the headlamp switch status from the headlamp switch. The SJB
receives the LH front door ajar status from the LH front door ajar switch through hardwired circuitry.
The headlamps on warning chime sounds when the LH front door is opened with the ignition switch in the
OFF position, no key-in-ignition input, and the headlamp switch is in the PARK or HEADLAMP ON
position. The SJB communicates the headlamp on chime request to the Instrument Panel Cluster (IPC) over
the Medium Speed Controller Area Network (MS-CAN) communication bus. The autolamps feature must not
be selected for the headlamps on warning chime to operate.
• Door ajar indication

• SJB
• IPC
PINPOINT TEST BA: THE HEADLAMPS ON WARNING CHIME IS INOPERATIVE

BA1 CHECK THE SAFETY BELT
Yes
• Ignition OFF. GO to BA2 .
• Ignition ON.
• Monitor the safety belt warning No
chime when the ignition switch is INSTALL a new IPC . REFER to Instrument Panel Cluster
transitioned from OFF to RUN (IPC) in this section. TEST the system for normal operation.
for 6 seconds.
• Does the safety belt warning
chime operate for
approximately 6 seconds?
BA2 CHECK THE EXTERIOR
LAMPS OPERATION
Yes
• Ignition OFF. GO to BA3 .
• Place the headlamp switch in the
PARK position. No
• Do the parking lamps operate? REFER to Section 417-01 .
BA3 CHECK THE MESSAGE
CENTER OPERATION
Yes
• Close all doors, hood and luggage INSTALL a new SJB . REFER to Section 419-10 . TEST the
compartment lid. system for normal operation.
• Ignition ON.
• Open the driver door while No
monitoring the message center GO to Pinpoint Test AA to diagnose the door/hood ajar
displays. warning indicator (non-hybrid) or GO to Pinpoint Test AR to
• Does the message center display diagnose the door ajar message center warning indicator
DRIVER DOOR AJAR? (MKZ or hybrid).

Pinpoint Test BB: The Turn Signal On Warning Chime Is Inoperative
Normal Operation
The turn signal on warning chime sounds when the vehicle travels more than 3.2 km (2.0 miles) with the turn
signal on. The Smart Junction Box (SJB) communicates the turn signal switch status to the Instrument Panel
Cluster (IPC) over the Medium Speed Controller Area Network (MS-CAN). The IPC receives the odometer
rolling count data from the PCM over the High Speed Controller Area Network (HS-CAN).
• Odometer operation
• IPC
PINPOINT TEST BB: THE TURN SIGNAL ON WARNING CHIME IS INOPERATIVE

BB1 CHECK THE KEY-IN-IGNITION WARNING
CHIME OPERATION
Yes
• Ignition OFF. GO to BB2 .
• Insert the key into the ignition lock cylinder.
• Open the LH front door and observe the No
key-in-ignition warning chime operation. GO to Pinpoint Test AY (chime is always on)
• Does the key-in-ignition warning chime or GO to Pinpoint Test AZ (chime is
operate correctly? inoperative).
BB2 CHECK THE TURN SIGNAL INDICATORS
OPERATION
Yes
• Ignition ON. GO to BB3 .
• Verify the turn signal indicators operation.
• Do the turn signal indicators operate No
correctly? GO to Pinpoint Test AB .
BB3 CHECK THE ODOMETER FOR CORRECT
OPERATION
Yes
• Drive the vehicle and observe the odometer for INSTALL a new SJB . REFER to Section
correct operation. 419-10 . TEST the system for normal
• Does the odometer operate correctly? operation.
No
GO to Pinpoint Test H .
Pinpoint Test BC: The Safety Belt Warning Chime Does Not Operate Correctly/The Belt-Minder®
Feature Does Not Operate Correctly
Normal Operation
The Instrument Panel Cluster (IPC) receives the safety belt and Belt-Minder® requests from the Restraints
Control Module (RCM) over the High Speed Controller Area Network (HS-CAN). The safety belt warning
PINPOINT TEST BA: THE HEADLAMPS ON WARNING CHIME IS INOPERATIVE 5303

chime sounds for approximately 6 seconds when the driver safety belt is not fastened and the ignition is
switched from the OFF or ACC to the RUN position.
The Belt-Minder® feature supplements the safety belt warning function and is enabled after the safety belt
warning is complete. The Belt-Minder® simultaneously sounds the chime and illuminates the safeelt warning
lamp in the IPC once the vehicle speed has exceeded 9.7 km/h (6 mph), and remains active for 5 minutes from
the time it is started.
There are 2 Belt-Minder® strategies that are used and implemented by the IPC as commanded by the RCM .
The 2 strategies are designed to provide an increased chime tone safety belt warning indicator flash activity.
Belt-Minder® A provides 6 one-second sequences for the first minute of the Belt-Minder® warning.
Belt-Minder® B provides 6 one-second sequences of 3 chime tones in rapid succession for the remainder of
the Belt-Minder® warning.
NOTE: Whenever the vehicle is operated using MyKey®, the RCM enables the Belt-Minder®.
If the Belt-Minder® is deactivated using an administrator key and driven using a MyKey® key, the MyKey®
system overrides the deactivation of Belt-Minder®. When MyKey® is in use, the driver cannot configure the
Belt-Minder® off. Once the Belt-Minder® is activated, the Belt-Minder® continues to chime periodically
(does not time out after 5 minutes) and the audio system is muted until the driver safety belt is fastened. Refer
to Section 419-01B for more information on the MyKey® feature.
NOTE: Make sure that the Belt-Minder® chime operation is verified with the vehicle moving at least 9.7
km/h (6 mph).
• Safety belt warning indication concern

• Belt-Minder® deactivated
• Speedometer concern
• IPC
PINPOINT TEST BC: THE SAFETY BELT WARNING CHIME IS INOPERATIVE/THE BELT-MINDER® FEATURE
DOES NOT OPERATE CORRECTLY

BC1 CHECK THE KEY-IN-IGNITION WARNING CHIME
OPERATION
Yes
• Ignition OFF. GO to BC2 .
• Open the LH front door and observe the key-in-ignition No
warning chime operation. INSTALL a new IPC . REFER to
• Does the key-in-ignition warning chime operate Instrument Panel Cluster (IPC) in
correctly? this section. TEST the system for
normal operation.
BC2 CHECK THE DRIVER SAFETY BELT BUCKLE
SWITCH
Yes
• Ignition ON. GO to BC3 .
• Enter the following diagnostic mode on the scan tool: RCM
PIDs. No

• Monitor the RCM driver safety belt buckle PID REFER to Section 501-20B .
(SBELT_D_ST) while buckling and unbuckling the driver
safety belt.
• Does the PID display BUCKLED with the safety belt
buckled and UNBUCKLED with the safety belt
unbuckled?
BC3 CHECK THE SAFETY BELT WARNING INDICATOR
FOR CORRECT OPERATION
Yes
• Ignition ON. GO to BC4 .
• Within one minute, buckle the LH front safety belt.
• With the engine running, verify the safety belt warning No
indicator illuminates with the safety belt unbuckled and GO to Pinpoint Test X .
turns off when buckled.
• Does the safety belt warning indicator operate correctly?
BC4 CHECK THE SPEEDOMETER OPERATION
Yes
• Verify that the speedometer is operating correctly. GO to BC5 .
• Does the speedometer operate correctly?
No
GO to Pinpoint Test F .
BC5 CHECK THE BELT-MINDER® CONFIGURATION
Yes
NOTE: Verify that an administrator key is used for this test If the Belt-Minder® is always on
and not a MyKey® programmed key. When a MyKey® above 5 km/h (3 mph) with the
programmed key is used, the Belt-Minder® is automatically safety belt unfastened, the system
turned on and cannot be disabled (if previously disabled by is operating normally.
an administrator, the Belt-Minder® remains disabled when
an administrator key is used). If the Belt-Minder® is always on
with the safety belt fastened or
• Verify that the Belt-Minder® is activated or configured on never on with the safety belt
for the seating position in question. Refer to Belt-Minder® unfastened above 9.7 km/h (6
Deactivating/Activating in this section to configure without mph), INSTALL a new RCM .
a scan tool. REFER to Section 501-20B . TEST
• Is the Belt-Minder® activated for the seating position in the system for normal operation.
question?
No
ACTIVATE the Belt-Minder® for
thesition in question. REFER to
Belt-Minder®
Deactivating/Activating in this
normal operation.
Pinpoint Test BD: The Parking Brake Warning Chime Is Inoperative
Normal Operation
The Instrument Panel Cluster (IPC) uses vehicle speed data sent from the PCM over the High Speed
Controller Area Network (HS-CAN) communication bus and the parking brake switch status sent from the
Smart Junction Box (SJB) over the Medium Speed Controller Area Network (MS-CAN) to determine when to
turn on the parking brake warning chime.
PINPOINT TEST BC: THE SAFETY BELT WARNING CHIME IS INOPERATIVE/THE BELT-MINDER®
5305 FEA
The SJB monitors and uses the ignition ON position, the parking brake on status, and vehicle speed that is
greater than 5 km/h (3 mph). The parking brake warning chime stops sounding and resets if the parking brake
is released, the ignition is not in the ON position, if the vehicle speed is below 5 km/h (3 mph), or after 90
seconds from the time the chime is activated.
NOTE: Make sure that the brake warning chime operation is verified with the vehicle moving at least 5 km/h
(3 mph) with the parking brake slightly applied (just enough to turn the brake warning indicator on).
• Brake warning indication concern

• Speedometer concern
• IPC
PINPOINT EST BD: THE PARKING BRAKE WARNING CHIME IS INOPERATIVE

BD1 CHECK THE KEY-IN-IGNITION
Yes
• Ignition OFF. GO to BD2 .
• Insert the key into the ignition lock
cylinder. No
• Open the LH front door and observe the INSTALL a new IPC . REFER to Instrument Panel
key-in-ignition warning chime operation. Cluster (IPC) in this section. TEST the system for
• Does the key-in-ignition warning chime normal operation.
operate correctly?
BD2 CHECK THE BRAKE WARNING
INDICATOR FOR CORRECT OPERATION
Yes
• Ignition ON. GO to BD3 .
• Apply and release the parking brake.
• Does the brake warning indicator turn No
on when applied and turn off when GO to Pinpoint Test S (never on) or GO to Pinpoint
released? Test T (always on).
BD3 CHECK THE SPEEDOMETER FOR
CORRECT OPERATION
Yes
• Ignition ON. GO to BD4 .
• Drive the vehicle and verify that the
speedometer is operating correctly. No
• Does the speedometer operate GO to Pinpoint Test F .
correctly?
BD4 RETRIEVE THE RECORDED DTCs
FROM THE SJB SELF-TEST
Yes
• Check for recorded DTCs from the SJB REFER to Section 419-10 .
self-test.

Cluster (IPC) in this section. TEST the system for

normal operation.
Pinpoint Test BE: The Memory Feedback Warning Chime Is Inoperative
Normal Operation
The Instrument Panel Cluster (IPC) receives the memory feedback chime request from the Driver Seat
Module (DSM) over the Medium Speed Controller Area Network (MS-CAN) communication bus. When a
successful memory set procedure is carried out, the DSM sends a chime request to the IPC to sound the
memory feedback chime.
• DSM
• IPC
PINPOINT TEST BE: THE MEMORY FEEDBACK WARNING CHIME IS INOPERATIVE

BE1 CHECK THE KEY-IN-IGNITION
Yes
• Ignition OFF. GO to BE2 .
• Open the LH front door and observe the No
key-in-ignition warning chime operation. GO to Pinpoint Test AZ .
• Does the key-in-ignition warning chime
operate correctly?
BE2 CHECK THE MEMORY SET FEATURE
Yes
• Verify that the memory set procedure can GO to BE3 .
successfully change the memory preferences.
• Does the memory set procedure No
successfully change the memory REFER to Section 501-10 .
preferences?
BE3 RETRIEVE THE RECORDED DTCs
Yes
• Check for recorded DTCs from the IPC REFER to DTC Charts in this section.
self-test.
INSTALL a new DSM . REFER to Section
Pinpoint Test BF: DTC U0100:00
Normal Operation
PINPOINT EST BD: THE PARKING BRAKE WARNING CHIME IS INOPERATIVE 5307
• DTC U0100:00 (Lost Communication With ECM /PCM "A": No Sub-Type Information) - sets in the
Instrument Panel Cluster (IPC) if data messages received from the PCM over the High Speed
Controller Area Network (HS-CAN) are missing for greater than 5 seconds. For a complete list of all
network messages, refer to Section 418-00 .
NOTE: Once the IPC sets DTC U0100:00, multiple gauges or indicators are likely to be inoperative in the
IPC . Other modules that require data from the IPC all set communication DTCs and may also exhibit system
function concer.
• PCM
• IPC
PINPOINT TEST BF: DTC U0100:00

BF1 VERIFY THAT THE SCAN TOOL
CAN COMMUNICATE WITH THE
PCM
Yes
• Connect the scan tool. GO to BF2 .
• Check that a vehicle session can be
established using the scan tool. No
• Can a vehicle session be REFER to Section 418-00 to diagnose no communication
established? with the PCM.
BF2 CHECK THE IPC CONTINUOUS
MEMORY DTCs
Yes
• Ignition ON. GO to BF3 .
on the scan tool: IPC Self-Test . No
• Clear the DTCs. Repeat the IPC The system is operating correctly at this time. The DTC
self-test. may have been set due to high network traffic or an
• Is DTC U0100:00 retrieved again? intermittent fault condition.
BF3 RETRIEVE THE RECORDED
Yes
• Check for recorded DTCs from the GO to Pinpoint Test BX (U3003:16) or GO to Pinpoint
IPC self-test. Test BY (U3003:17).
• Is DTC U3003:16 or DTC
U3003:17 recorded? No
GO to BF4 .
BF4 CHECK FOR DTC U0100:00 SET
IN OTHER MODULES
Yes
• Ignition ON. INSTALL a new PCM. REFER to Refer to the appropriate
• Enter the following diagnostic mode section in Group 303 for the procedure.. TEST the system
on the scan tool: Self-Test . for normal operation.
• Retrieve the continuous memory
PINPOINT TEST BE: THE MEMORY FEEDBACK WARNING CHIME IS INOPERATIVE 5308
DTCs from all modules. No

• Is DTC U0100:00 set in the INSTALL a new IPC . REFER to Instrument Panel Cluster
Restraints Control Module (IPC) in this section. TEST the system for normal
(RCM)? operation.
Pinpoint Test BG: DTC U0101:00
Normal Operation
• DTC U0101:00 (Lost Communication With TCM : No Sub-Type Information) - sets in the Instrument
Panel Cluster (IPC) if data messages received from the Transmission Control Module (TCM) over the
High Speed Controller Area Network (HS-CAN) are missing for greater than 5 seconds. For a
complete list of all network messages, refer to Section 418-00 .
• TCM
• IPC
PINPOINT TEST BG: DTC U0101:00

BG1 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to BG2 .
• Verify that there is an observable symptom
present. No
• Is an observable symptom present? The system is operating normally at this time. The
DTC may have been set due to high network traffic
or an intermittent fault condition.
BG2 CHECK THE COMMUNICATION
NETWORK
Yes
• Ignition ON. GO to BG3 .
scan tool: Network Test . No
• Carry out the network test. REFER to Section 418-00 .
• Does the TCM pass the network test?
BG3 RETRIEVE THE RECORDED DTCs
Yes
• Check for recorded DTCs from the IPC GO to Pinpoint Test BX (U3003:16) or GO to
self-test. Pinpoint Test BY (U3003:17).
• Is DTC U3003:16 or DTC U3003:17
recorded? No
GO to BG4 .
BG4 RECHECK THE IPC DTCs
Yes
• Clear the DTCs. Repeat the IPC self-test. GO to BG5 .
• Is DTC U0101:00 still present?
PINPOINT TEST BF: DTC U0100:00 5309

No
The system is operating correctly at this time. The
BG5 CHECK FOR DTC U0101 SET IN
OTHER MODULES
Yes
• Clear all DTCs. For Aisin AW21 transaxle, INSTALL a new TCM .
• Ignition OFF. REFER to Section 307-01A . CLEAR the DTCs.
• Ignition ON. REPEAT the self-test.
• Wait 10 seconds.
• Enter the following diagnostic mode on the For the 6F35 transaxle, INSTALL a new PCM.
scan tool: Self-Test . REFER to Refer to the appropriate section in Group
• Retrieve the continuous memory DTCs 303 for the procedure..
from all modules.
• Is DTC U0101 set in the PCM? For the eCVT transaxle, INSTALL a new transaxle.
REFER to Section 307-01C . CLEAR the DTCs.
No
Cluster (IPC) in this section. TEST the system for
normal operation.
Pinpoint Test BH: DTC U0102:00
Normal Operation
• DTC U0102:00 (Lost Communication With Transfer Case Control Module: No Sub-Type
Information) - sets in the Instrument Panel Cluster (IPC) if data messages received from the 4X4
control module over the High Speed Controller Area Network (HS-CAN) are missing for greater than
5 seconds. For a complete list of all network messages, refer to Section 418-00 .

• IPC
PINPOINT TEST BH: DTC U0102:00

BH1 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to BH2 .
• Verify that there is an observable symptom present.
• Is an observable symptom present? No
The system is operating normally at this
time. The DTC may have been set due
to high network traffic or an
intermittent fault condition.
BH2 CHECK THE COMMUNICATION NETWORK
PINPOINT TEST BG: DTC U0101:00 5310


• Enter the following diagnostic mode on the scan tool: GO to BH3 .
Network Test .
• Carry out the network test. No
• Does the 4X4 control module pass the network test? REFER to Section 418-00 .
BH3 RETRIEVE THE RECORDED DTCs FROM THE
IPC SELF-TEST
Yes
• Check for recorded DTCs from the IPC self-test. GO to Pinpoint Test BX (U3003:16) or
• Is DTC U3003:16 or DTC U3003:17 recorded? GO to Pinpoint Test BY (U3003:17).
No
GO to BH4 .
BH4 RECHECK THE IPC DTCs
Yes
NOTE: If new modules were installed prior to the DTC GO to BH5 .
being set, the module configuration may be incorrectly
set during the Programmable Module Installation (PMI) No
or the PMI may not have been carried out. The system is operating correctly at this
• Clear the DTCs. Repeat the IPC self-test. to high network traffic or an
• Is DTC U0102:00 still present? intermittent fault condition.
BH5 CHECK FOR DTC U0114, U0114:00 or U1900 SET
IN OTHER MODULES
Yes
• Clear all DTCs. INSTALL a new 4X4 control module.
• Ignition OFF. REFER to Section 308-07A . CLEAR
• Ignition ON. the DTCs. REPEAT the self-test.
• Enter the following diagnostic mode on the scan tool: No
Self-Test . INSTALL a new IPC . REFER to
• Retrieve the continuous memory DTCs from all Instrument Panel Cluster (IPC) . TEST
modules. the system for normal operation.
• Is DTC U0114, U0114:00 or U1900 set in the ABS?
Pinpoint Test BI: DTC U010F:00
Normal Operation
• DTC U010F:00 (Lost Communication With Air Conditioning Control Module: No Sub-Type
Information) - sets in the Instrument Panel Cluster (IPC) if data messages received from the HVAC
module over the Medium Speed Controller Area Network (MS-CAN) are missing for greater than 5
seconds. For a complete list of all network messages, refer to Section 418-00 .
• HVAC module
• IPC
PINPOINT TEST BH: DTC U0102:00 5311

PINPOINT TEST BI: DTC U010F:0

BI1 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to BI2 .
time. The DTC may have been set due to
high network traffic or an intermittent
fault condition.
BI2 CHECK THE COMMUNICATION NETWORK
Yes
• Ignition ON. GO to BI3 .
Network Test . No
• Does the HVAC module pass the network test?
BI3 RETRIEVE THE RECORDED DTCs FROM THE
IPC SELF-TEST
Yes
No
GO to BI4 .
BI4 RECHECK THE IPC DTCs
Yes
NOTE: If new modules were installed prior to the INSTALL a new HVAC module. REFER
DTC being set, the module configuration may be to Section 412-01 . CLEAR the DTCs.
incorrectly set during the Programmable Module REPEAT the IPC self-test.
Installation (PMI) or the PMI may not have been
carried out. If DTC U010F:00 is still present,
• Clear the DTCs. Repeat the IPC self-test. Instrument Panel Cluster (IPC) in this
• Is DTC U010F:00 still present? section. TEST the system for normal
operation.
No
The system is operating correctly at this
fault condition.
Pinpoint Test BJ: DTC U0111:00
Normal Operation
• DTC U0111:00 (Lost Communication With Battery Energy Control Module "A": No Sub-Type
Information) - sets in the Instrument Panel Cluster (IPC) if data messages received from the Battery
Pack Sensor Module (BPSM) over the High Speed Controller Area Network (HS-CAN) are missing
PINPOINT TEST BI: DTC U010F:0 5312

for greater than 5 seconds. For a complete list of all network messages, refer to Section 418-00 .
• BPSM
• IPC
PINPOINT TEST BJ: DTC U0111:00

BJ1 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to BJ2 .
BJ2 CHECK THE COMMUNICATION NETWORK
Yes
• Ignition ON. GO to BJ3 .
Network Test . No
• Does the BPSM pass the network test?
BJ3 RETRIEVE THE RECORDED DTCs FROM THE
IPC SELF-TEST
Yes
No
GO to BJ4 .
BJ4 RECHECK THE IPC DTCs
Yes
NOTE: If new modules were installed prior to the DTC GO to BJ5 .
BJ5 CHECK FOR DTC U0111 SET IN OTHER
MODULES
Yes
• Clear all DTCs. INSTALL a new BPSM . REFER to
• Ignition OFF. Section 414-03 . CLEAR the DTCs.
PINPOINT TEST BJ: DTC U0111:00 5313


Self-Test . INSTALL a new IPC . REFER to
• Retrieve the continuous memory DTCs from all Instrument Panel Cluster (IPC) in this
modules. section. TEST the system for normal
• Is DTC U0111 set in the PCM? operation.
Pinpoint Test BK: DTC U0121:00
Normal Operation
• DTC U0121:00 (Lost Communication With Anti-Lock Brake System [ABS] Control Module: No
Sub-Type Information) - sets in the Instrument Panel Cluster (IPC) if data messages received from the
ABS module over the High Speed Controller Area Network (HS-CAN) are missing. For a complete
list of all network messages, refer to Section 418-00 .
• ABS module
• IPC
PINPOINT TEST BK: DTC U0121:00

BK1 VERIFY THE CUSTOMER
CONCERN
Yes
• Ignition ON. GO to BK2 .
• Verify that there is an observable
symptom present. No
DTC may have been set due to high network traffic or
an intermittent fault condition.
BK2 CHECK THE COMMUNICATION
NETWORK
Yes
• Ignition ON. GO to BK3 .
the scan tool: Network Test . No
• Does the ABS module pass the
network test?
BK3 RETRIEVE THE RECORDED DTCs
Yes
• Is DTC U3003:16 or DTC U3003:17
recorded? No
GO to BK4 .
BK4 RECHECK THE IPC DTCs
PINPOINT TEST BK: DTC U0121:00 5314

• Clear the DTCs. Repeat the IPC self-test. Yes

• Is DTC U0121:00 still present? INSTALL a new ABS module. REFER to Section
206-09 . CLEAR the DTCs. REPEAT the IPC
self-test.
If DTC U0121:00 is still present, INSTALL a new

IPC . REFER to Instrument Panel Cluster (IPC) in this
section. TEST the system for normal operation.
No
Pinpoint Test BL: DTC U0131:00
Normal Operation
• DTC U0131:00 (Lost Communication With Power Steering Control Module: No Sub-Type
Information) - sets in the Instrument Panel Cluster (IPC) if data messages received from the Power
Steering Control Module (PSCM) over the High Speed Controller Area Network (HS-CAN) are
missing for greater than 5 seconds. For a complete list of all network messages, refer to Section
418-00 .
• PSCM
• IPC
PINPOINT TEST BL: DTC U0131:00

BL1 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to BL2 .
BL2 CHECK THE COMMUNICATION NETWORK
Yes
• Ignition ON. GO to BL3 .
Network Test . No
• Does the PSCM pass the network test?
BL3 RETRIEVE THE RECORDED DTCs FROM THE
IPC SELF-TEST
PINPOINT TEST BL: DTC U0131:00 5315

• Check for recorded DTCs from the IPC self-test. Yes

• Is DTC U3003:16 or DTC U3003:17 recorded? GO to Pinpoint Test BX (U3003:16) or
GO to Pinpoint Test BY (U3003:17).
No
GO to BL4 .
BL4 RECHECK THE IPC DTCs
Yes
NOTE: If new modules were installed prior to the DTC GO to BL5 .
BL5 CHECK FOR DTC U0131:00 SET IN OTHER
MODULES
Yes
• Clear all DTCs. INSTALL a new PSCM (part of the
• Ignition OFF. steering gear). REFER to Section
• Ignition ON. 211-02 . CLEAR the DTCs. REPEAT
• Wait 10 seconds. the self-test.
Self-Test . No
• Retrieve the continuous memory DTCs from all INSTALL a new IPC . REFER to
modules. Instrument Panel Cluster (IPC) in this
• Is DTC U0131:00 set in the ABS module? section. TEST the system for normal
operation.
Pinpoint Test BM: DTC U0140:00
Normal Operation
• DTC U0140:00 (Lost Communication With Body Control Module: No Sub-Type Information) - sets
in the Instrument Panel Cluster (IPC) if data messages received from the Smart Junction Box (SJB)
over the Medium Speed Controller Area Network (MS-CAN) are missing. For a complete list of all
network messages, refer to Section 418-00 .
• SJB
• IPC
PINPOINT TEST BM: DTC U0140:00

BM1 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to BM2 .
present. No
PINPOINT TEST BM: DTC U0140:00 5316

• Is an observable symptom present? The system is operating normally at this time.

The DTC may have been set due to high network
traffic or an intermittent fault condition.
BM2 CHECK THE COMMUNICATION
NETWORK
Yes
• Ignition ON. GO to BM3 .
• Does the SJB pass the network test?
BM3 RETRIEVE THE RECORDED DTCs
Yes
• Is DTC U3003:16 or DTC U3003:17
recorded? No
GO to BM4 .
BM4 RECHECK THE IPC DTCs
Yes
• Clear the DTCs. Repeat the IPC self-test. GO to BM5 .
No
The system is operating correctly at this time.
The DTC may have been set due to high network
traffic or an intermittent fault condition.
BM5 CHECK FOR DTC U0140 SET IN OTHER
MODULES
Yes
• Clear all DTCs. INSTALL a new SJB . REFER to Section 419-10
• Ignition OFF. . CLEAR the DTCs. REPEAT the self-test.
• Ignition ON.
• Wait 10 seconds. No
• Enter the following diagnostic mode on the INSTALL a new IPC . REFER to Instrument
scan tool: Self-Test . Panel Cluster (IPC) in this section. TEST the
• Retrieve the continuous memory DTCs from system for normal operation.
all modules.
• Is DTC U0140 set in the Driver Seat
Module (DSM) or the Driver Door Module
(DDM)?
Pinpoint Test BN: DTC U0151:00
Normal Operation
• DTC U0151:00 (Lost Communication With Restraints Control Module: No Sub-Type Information) -
sets in the Instrument Panel Cluster (IPC) if data messages received from the Restraints Control
Module (RCM) over the High Speed Controller Area Network (HS-CAN) are missing. For a complete
list of all network messages, refer to Section 418-00 .
Ts pinpoint test is intended to diagnose the following:
PINPOINT TEST BM: DTC U0140:00 5317

• RCM
• IPC
PINPOINT TEST BN: DTC U0151:00

BN1 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to BN2 .
present. No
BN2 CHECK THE COMMUNICATION
NETWORK
Yes
• Ignition ON. GO to BN3 .
• Does the RCM pass the network test?
BN3 RETRIEVE THE RECORDED DTCs
Yes
• Is DTC U3003:16 or DTC U3003:17
recorded? No
GO to BN4 .
BN4 RECHECK THE IPC DTCs
Yes
• Clear the DTCs. Repeat the IPC self-test. GO to BN5 .
No
BN5 CHECK FOR DTC U0151:00 SET IN
OTHER MODULES
Yes
• Clear all DTCs. INSTALL a new RCM . REFER to Section
• Ignition OFF. 501-20B . CLEAR the DTCs. REPEAT the
scan tool: Self-Test . INSTALL a new IPC . REFER to Instrument Panel
• Retrieve the continuous memory DTCs Cluster (IPC) in this section. TEST the system for
from all modules. normal operation.
PINPOINT TEST BN: DTC U0151:00 5318

• Is DTC U0151:00 set in the Occupant

Classification System Module (OCSM)?
Pinpoint Test BO: DTC U0154:00
Normal Operation
• DTC U0154:00 (Lost Communication With Occupant Classification Sensor [ OCS ]: No Sub-Type
Information) - sets in the Instrument Panel Cluster (IPC) if data messages received from the Occupant
Classification System Module (OCSM) over the High Speed Controller Area Network (HS-CAN) are
missing. For a complete list of all network messages, refer to Section 418-00 .
• OCSM
• IPC
PINPOINT TEST BO: DTC U0154:00

BO1 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to BO2 .
present. No
BO2 CHECK THE COMMUNICATION
NETWORK
Yes
• Ignition ON. GO to BO3 .
• Does the OCSM pass the network test?
BO3 RETRIEVE THE RECORDED DTCs
Yes
• Is DTC U3003:16 or DTC U3003:17
recorded? No
GO to BO4 .
BO4 RECHECK THE IPC DTCs
Yes
• Clear the DTCs. Repeat the IPC self-test. GO to BO5 .
No
PINPOINT TEST BO: DTC U0154:00 5319


BO5 CHECK FOR DTC U0154:00 SET IN
OTHER MODULES
Yes
• Clear all DTCs. INSTALL a new OCSM . REFER to Section
• Ignition OFF. 501-20B . CLEAR the DTCs. REPEAT the self-test.
• Ignition ON.
• Enter the following diagnostic mode on the INSTALL a new IPC . REFER to Instrument Panel
scan tool: Self-Test . Cluster (IPC) in this section. TEST the system for
• Retrieve the continuous memory DTCs normal operation.
from all modules.
• Is DTC U0154:00 set in the Restraints
Control Module (RCM) module?
Pinpoint Test BP: DTC U0159:00
Normal Operation
• DTC U0159:00 (Lost Communication With Parking Assist Control Module "A": No Sub-Type
Information) - sets in the Instrument Panel Cluster (IPC) if data messages received from the Parking
Aid Module (PAM) over the Medium Speed Controller Area Network (MS-CAN) are missing. For a
This pinpoint test is intended to diagnose e following:
• PAM
• IPC
PINPOINT TEST BP: DTC U0159:00

BP1 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to BP2 .
The system is operating normally
at this time. The DTC may have
been set due to high network traffic
BP2 CHECK THE COMMUNICATION NETWORK
Yes
• Ignition ON. GO to BP3 .
Network Test . No
• Does the PAM pass the network test?
BP3 RETRIEVE THE RECORDED DTCs FROM THE IPC
PINPOINT TEST BP: DTC U0159:00 5320

SELF-TEST
Yes
• Check for recorded DTCs from the IPC self-test. GO to Pinpoint Test BX
• Is DTC U3003:16 or DTC U3003:17 recorded? (U3003:16) or GO to Pinpoint Test
BY (U3003:17).
No
GO to BP4 .
BP4 RECHECK THE IPC DTCs
Yes
NOTE: If new modules were installed prior to the DTC INSTALL a new PAM . REFER to
being set, the module configuration may be incorrectly set Section 413-13 . CLEAR the
during the Programmable Module Installation (PMI) or the DTCs. REPEAT the IPC self-test.
PMI may not have been carried out.
If DTC U0159:00 is still present,
• Clear the DTCs. Repeat the IPC self-test. INSTALL a new IPC . REFER to
• Is DTC U0159:00 still present? Instrument Panel Cluster (IPC) in
normal operation.
No
The system is operating correctly at
this time. The DTC may have been
set due to high network traffic or
Pinpoint Test BQ: DTC U0163:00
Normal Operation
• DTC U0163:00 (Lost Communication With Navigation Control Module: No Sub-Type Information) -
sets in the Instrument Panel Cluster (IPC) if data messages received from the Audio Front Control
Module (ACM) over the High Speed Controller Area Network (HS-CAN) are missing. For a
• ACM
• IPC
PINPOINT TEST BQ: DTC U0163:00

BQ1 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to BQ2 .
The system is operating normally at
set due to high network traffic or an
PINPOINT TEST BQ: DTC U0163:00 5321

BQ2 CHECK THE COMMUNICATION NETWORK

Yes
• Ignition ON. GO to BQ3 .
Network Test . No
• Does the ACM pass the network test?
BQ3 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Yes
BY (U3003:17).
No
GO to BQ4 .
BQ4 RECHECK THE IPC DTCs
Yes
NOTE: If new modules were installed prior to the DTC INSTALL a new ACM . REFER to
being set, the module configuration may be incorrectly set Section 415-00 . CLEAR the DTCs.
during the Programmable Module Installation (PMI) or the REPEAT the IPC self-test.
normal operation.
No
Pinpoint Test BR: DTC U0164:00
Normal Operation
• DTC U0164:00 (Lost Communication With HVAC Control Module: No Sub-Type Information) - sets
in the Instrument Panel Cluster (IPC) if data messages received from the HVAC module over the
Medium Speed Controller Area Network (MS-CAN) are missing. For a complete list of all network
messages, refer to Section 418-00 .
• HVAC module
• IPC
PINPOINT TEST BR: DTC U0164:00

BR1 VERIFY THE CUSTOMER CONCERN
PINPOINT TEST BR: DTC U0164:00 5322


• Verify that there is an observable symptom present. GO to BR2 .
• Is an observable symptom present?
No
BR2 CHECK THE COMMUNICATION NETWORK
Yes
• Ignition ON. GO to BR3 .
Network Test . No
• Does the HVAC module pass the network test?
BR3 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Yes
BY (U3003:17).
No
GO to BR4 .
BR4 RECHECK THE IPC DTCs
Yes
NOTE: If new modules were installed prior to the DTC INSTALL a new HVAC module.
being set, the module configuration may be incorrectly set REFER to Section 412-01 .
during the Programmable Module Installation (PMI) or the CLEAR the DTCs. REPEAT the
PMI may not have been carried out. IPC self-test.
• Clear the DTCs. Repeat the IPC self-test. If DTC U0164:00 is still present,
• Is DTC U0164:00 still present? INSTALL a new IPC . REFER to
Instrument Panel Cluster (IPC) in
normal operation.
No
Pinpoint Test BS: DTC U0184:00
Normal Operation
• DTC U0184:00 (Lost Communication With Radio: No Sub-Type Information) - sets in the Instrument
Panel Cluster (IPC) if data messages received from the Audio Front Control Module (ACM) over the
High Speed Controller Area Network (HS-CAN) are missing for greater than 5 seconds. For a
PINPOINT TEST BR: DTC U0164:00 5323

• ACM
• IPC
PINPOINT TEST BS: DTC U0184:00

BS1 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to BS2 .
BS2 CHECK THE COMMUNICATION NETWORK
Yes
• Ignition ON. GO to BS3 .
Network Test . No
BS3 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Yes
BY (U3003:17).
No
GO to BS4 .
BS4 RECHECK THE IPC DTCs
Yes
NOTE: If new modules were installed prior to the DTC INSTALL a new ACM . REFER to
normal operation.
No
PINPOINT TEST BS: DTC U0184:00 5324

Pinpoint Test BT: DTC U0208:00
Normal Operation
• DTC U0208:00 (Lost Communication With "Seat Control Module A": No Sub-Type Information) -
sets in the Instrument Panel Cluster (IPC) if data messages received from the Driver Seat Module
(DSM) over the Medium Speed Controller Area Network (MS-CAN) are missing. For a complete list
of all network messages, refer to Section 418-00 .
• DSM
i>IPC
PINPOINT TEST BT: DTC U0208:00

BT1 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to BT2 .
BT2 CHECK THE COMMUNICATION NETWORK
Yes
• Ignition ON. GO to BT3 .
Network Test . No
• Does the DSM pass the network test?
BT3 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Yes
BY (U3003:17).
No
GO to BT4 .
BT4 RECHECK THE IPC DTCs
Yes
NOTE: If new modules were installed prior to the DTC INSTALL a new DSM . REFER to
PINPOINT TEST BT: DTC U0208:00 5325

normal operation.
No
Pinpoint Test BU: DTC U0232:00
Normal Operation
• DTC U0232:00 (Lost Communication With Side Obstacle Detection Control Module Left: No
Side Obstacle Detection Control Module - Left (SOD-L) over the High Speed Controller Area
Network (HS-CAN) are missing for greater than 5 seconds. For a complete list of all network
• SOD-L
• IPC
PINPOINT TEST BU: DTC U0232:00

BU1 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to BU2 .
BU2 CHECK THE COMMUNICATION NETWORK
Yes
• Ignition ON. GO to BU3 .
Network Test . No
• Does the SOD-L pass the network test?
BU3 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Yes
BY (U3003:17).
No
GO to BU4 .
PINPOINT TEST BU: DTC U0232:00 5326

BU4 RECHECK THE IPC DTCs

Yes
NOTE: If new modules were installed prior to the DTC INSTALL a new SOD-L . REFER
being set, the module configuration may be incorrectly set to Section 419-04 . CLEAR the
normal operation.
No
Pinpoint Test BV: DTC U0233:00
Normal Operation
• DTC U0233:00 (Lost Communication With Side Obstacle Detection Control Module Right: No
Side Obstacle Detection Control Module - Right (SOD-R) over the High Speed Controller Area
Network (HS-CAN) are missing for greater than 5 seconds. For a complete list of all network
• SOD-R
• IPC
PINPOINT TEST BV: DTC U0233:00

BV1 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to BV2 .
BV2 CHECK THE COMMUNICATION NETWORK
Yes
• Ignition ON. GO to BV3 .
Network Test . No
PINPOINT TEST BV: DTC U0233:00 5327

• Does the SOD-R pass the network test?

BV3 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Yes
BY (U3003:17).
No
GO to BV4 .
BV4 RECHECK THE IPC DTCs
Yes
NOTE: If new modules were installed prior to the DTC INSTALL a new SOD-R . REFER
being set, the module configuration may be incorrectly set to Section 419-04 . CLEAR the
normal operation.
No
Pinpoint Test BW: DTC U0298:00
Normal Operation
• DTC U0298:00 (Lost Communication With DC to DC Control Module "A": No Sub-Type
Information) - sets in the Instrument Panel Cluster (IPC) if data messages received from the DC to
DC Converter Control Module (DC/DC) over the Medium Speed Controller Area Network
(MS-CAN) are missing. For a complete list of all network messages, refer to Section 418-00 .
• DC to DC Converter Control Module (DC/DC)

• IPC
PINPOINT TEST BW: DTC U0298:00

BW1 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to BW2 .
PINPOINT TEST BW: DTC U0298:00 5328


faulcondition.
BW2 CHECK THE COMMUNICATION NETWORK
Yes
• Ignition ON. GO to BW3 .
tool: Network Test . No
• Does the DC/DC pass the network test?
BW3 RETRIEVE THE RECORDED DTCs FROM
THE IPC SELF-TEST
Yes
No
GO to BW4 .
BW4 RECHECK THE IPC DTCs
Yes
NOTE: If new modules were installed prior to the INSTALL a new DC/DC . REFER to
DTC being set, the module configuration may be Section 414-05 . CLEAR the DTCs.
incorrectly set during the Programmable Module REPEAT the IPC self-test.
Installation (PMI) or the PMI may not have been
carried out. If DTC U0298:00 is still present,
• Clear the DTCs. Repeat the IPC self-test. Instrument Panel Cluster (IPC) in this
• Is DTC U0298:00 still present? section. TEST the system for normal
operation.
No
fault condition.
Pinpoint Test BX: DTC U3003:16
Normal Operation
• DTC U3003:16 (Battery Voltage: Circuit Voltage Below Threshold) - sets in the Instrument Panel
Cluster (IPC) in continuous memory if the IPC detects battery voltage below 9 volts on the voltage
input circuit.

• High circuit resistance
• IPC
PINPOINT TEST BW: DTC U0298:00 5329

PINPOINT TEST BX: DTC U3003:16
Section 414-01 .

BX1 RECHECK THE IPC DTCs
Yes
• Ignition ON. GO to BX2 .
tool: IPC Self-Test . No
• Clear the DTCs. Repeat the IPC self-test. The system is operating correctly at this
• Is DTC U3003:16 still present? time. The DTC may have been set due to a
previous low battery voltage condition.
BX2 CHECK FOR CHARGING SYSTEM DTCs IN
THE PCM
Yes
• Enter the following diagnostic mode on the scan REFER to Section 414-00 .
tool: PCM Self-Test .
• Carry out the PCM Key ON Engine OFF (KOEO) No
self-test. GO to BX3 .
• Retrieve the continuous memory DTCs from all
modules.
• Is DTC P0620, P0622, P0625, P0626 or P065B set
in the PCM?
BX3 CHECK THE BATTERY CONDITION AND
STATE OF CHARGE
Yes
• Check the battery condition and verify that the GO to BX4 .
battery is fully charged. Refer to Section 414-01 .
• Is the battery OK and fully charged? No
BX4 CHECK THE IPC VOLTAGE INPUT
Yes
• Measure and record the voltage at the battery. GO to BX7 .
• Select the IPC voltage input PID GO to BX5 .
(MODULE_VOLT). Monitor the voltage PID and
compare the reading with the recorded battery
voltage.
• Is the voltage within 0.2 volt of the recorded
battery voltage?
BX5 CHECK THE IPC VOLTAGE SUPPLY
PINPOINT TEST BX: DTC U3003:16 5330


• Disconnect: IPC C220 . GO to BX6 .
• Ignition ON.
• For non-hybrid, measure the voltage between the No
IPC C220-21, circuit SBP26 (YE/RD), harness side REPAIR circuit SBP26 (YE/RD) for high
and ground. resistance. CLEAR the DTC. REPEAT the
self-test.
• For hybrid, measure the voltage between the IPC

C220-19, circuit SBP26 (YE/RD), harness side and
ground.
• Is the voltage within 0.2 volt of the recorded

battery voltage?
BX6 CHECK THE IPC GROUND CIRCUIT
Yes
• Ignition OFF. GO to BX7 .
• On non-hybrid, measure the resistance between the No
IPC C220-5, circuit GD116 (BK/VT), harness side REPAIR circuit GD116 (BK/VT) for high
and ground. resistance. CLEAR the DTCs. REPEAT
the self-test.
• On hybrid, measure the resistance between the IPC

C220-9, circuit GD116 (BK/VT), harness side and
ground.
PINPOINT TEST BX: DTC U3003:16 5331


BX7 CHECK FOR CORRECT IPC OPERATION
Yes
• Check for: Instrument Panel Cluster (IPC) . TEST the
♦ damaged pins
• Connect the IPC connector and make sure it seats The system is operating correctly at this
correctly. time. The concern may have been caused
present.
Pinpoint Test BY: DTC U3003:17
Normal Operation
• DTC U3003:17 (Battery Voltage: Circuit Voltage Above Threshold) - sets in the Instrument Panel
Cluster (IPC) in continuous memory if the IPC detects battery voltage above 16 volts on the voltage
input circuit.

• IPC
PINPOINT TEST BY: DTC U3003:17
NOTE: DTC U3003:17 may be stored in the module memory due to past battery charging or vehicle jump
starting events.
BY1 CHECK FOR DTC B1317, B1676, P0563

(PCM) OR U3003:17 SET IN OTHER
MODULES
Yes
• Ignition ON. REFER to Section 414-00 to diagnose an
• Enter the following diagnostic mode on the overcharging condition.
scan tool: Self-Test .
PINPOINT TEST BY: DTC U3003:17 5332

• Retrieve the continuous memory DTCs from No

all modules. GO to BY2 .
• Is DTC B1317, B1676, P0563 (PCM) or
U3003:17 set in more than one module?
BY2 CHECK THE BATTERY VOLTAGE
Yes
• Turn off all interior/exterior lights and REFER to Section 414-00 to diagnose an
accessories. overcharging condition.
• Start and run the engine at approximately
2,000 rpm for 3 minutes while monitoring No
the battery voltage. GO to BY3 .
• Does the battery voltage rise to 15.5 volts
or higher?
BY3 RECHECK FOR DTC U3003:17
Yes
• Turn the engine off. INSTALL a new IPC . REFER to Instrument Panel
• Ignition ON. Cluster (IPC) in this section. TEST the system for
• Enter the following diagnostic mode on the normal operation.
scan tool: Self-Test .
• Clear the continuous memory DTCs. No
• Carry out the IPC self-test. The system is operating normally at this time. The
• Is DTC U3003:17 present? DTC may have been set previously during battery
charging or while jump starting the vehicle.
Pinpoint Test BZ: DTC U300A:62 Or U300A:64
Normal Operation
With the ignition switch in the START or RUN position, the Instrument Panel Cluster (IPC) receives a
RUN/START voltage input from the Smart Junction Box (SJB). The IPC also receives a networked ignition
status from the SJB over the Medium Speed Controller Area Network (MS-CAN) communication bus.
• DTC U300A:62 (Ignition Switch: Signal Compare Failure) - the IPC compares the networked input
with the hardwired input and sets DTC U300A:62 in continuous memory and on-demand if a
discrepancy is detected.
• DTC U300A:64 (Ignition Switch: Signal Plausibility Failure) - the IPC monitors the messaged
START status and sets DTC U300A:64 in continuous memory and on-demand if the IPC detects a
START input for 15 seconds. Once the fault condition is detected, the IPC retains limited
functionality for 15 seconds then returns to full functionality.

• SJB
• IPC

PINPOINT TEST BZ: DTC U300A:62 OR U300A:64

BZ1 RETRIEVE THE RECORDED DTCs FROM THE IPC
SELF-TEST
Yes
• Check for recorded DTCs from the IPC self-test. GO to BZ2 .
• Is DTC U300A:62 recorded?
No
GO to BZ3 .
BZ2 CHECK THE IPC VOLTAGE SUPPLY
Yes
• Ignition OFF. GO to BZ3 .
• Measure the voltage between the IPC C220-20, circuit No
CBP29 (WH/VT), harness side and the IPC C220-5, circuit VERIFY the SJB fuse 29 (5A) is
GD116 (BK/VT), harness side. OK. If OK, REPAIR the circuit for
an open. TEST the system for
normal operation. If not OK, REFER
to the Wiring Diagrams Manual to
identify the possible causes of the
circuit short.
• Ignition ON.
CBP29 (WH/VT), harness side and the IPC C220-5, circuit
• Place the ignition in the START position.

CBP29 (WH/VT), harness side and the IPC C220-5, circuit
PINPOINT TEST BZ: DTC U300A:62 OR U300A:64 5334

• Is the voltage 0 volts in the OFF position and greater

than 10 volts in the RUN and START positions?
BZ3 CHECK THE SJB INPUT PIDs FROM THE
IGNITION SWITCH
Yes
• Ignition ON. GO to BZ4 .
DataLogger . No
• Select the SJB PIDs ignition ACC (IGN_A_ECU), ignition REFER to Section 211-05 to
OFF (IGN_O_ECU), ignition RUN (IGN_R_ECU), and diagnose the ignition outputs to the
ignition START (IGN_S_ECU). Monitor the ignition PIDs SJB .
while switching the ignition from ACC, OFF, RUN and
START.
• Do the SJB PIDs match the ignition mode?
BZ4 CHECK THE IPC DTCs
Yes
• Enter the following diagnostic mode on the scan tool: IPC INSTALL a new SJB . REFER to
Self-Test . Section 419-10 . CLEAR the DTCs.
• Repeat the IPC self-test. Clear the DTCs. REPEAT the self-test.
• Is DTC U300A:62 or DTC U300A:64 still present?
If the DTC is still present, INSTALL
a new IPC . REFER to Instrument
Panel Cluster (IPC) in this section.
operation.
No
Pinpoint Test CA: The Compass Is Inoperative
Refer to Wiring Diagrams Cell 124 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Power Mirrors for
NOTE: This procedure is only applicable to vehicles without navigation. For vehicles with navigation, refer
to Section 415-00 .
Normal Operation
The compass module (integral to the auto-dimming interior mirror) provides vehicle directional inputs over
the compass communication circuits to the Instrument Panel Cluster (IPC), which sends the compass
information to the FDIM over the Medium Speed Controller Area Network (MS-CAN). The FDIM displays
the compass direction according to the information that has been provided by the compass module to the IPC .

• DTC U0161:00 (Lost Communication With Compass Module: No Sub Type Information) - sets when
the IPC does not receive any communication from the compass module for 5 seconds or longer.
• DTC U0462:68 (Invalid Data Received From Compass Module: Event Information) - sets when the
IPC attempts a self-test of the compass module and its associated circuits and a failure results.
This pinpoint test is intended to diagnose thelowing:
• Fuse(s)
• Compass module (integral to the auto-dimming interior mirror)
• FDIM (compass display)
• IPC
PINPOINT TEST CA: THE COMPASS IS INOPERATIVE
NOTE: Always set the zone and calibrate the compass before replacing an inaccurate compass module.

CA1 CHECK THE AUTO-DIMMING INTERIOR
MIRROR VOLTAGE SUPPLY
Yes
• Ignition OFF. GO to CA2 .
• Disconnect: Auto-Dimming Interior Mirror C911 or
C9039 (Camera Display Mirror). No
• Ignition ON. VERIFY the BCM fuse 32 (15A). If
• Measure the voltage between the auto-dimming interior OK, REPAIR circuit CBP32 (GN/VT)
mirror C911-1 or C9039-1 (camera display mirror), for an open. TEST the system for
circuit CBP41 (BU), harness side and ground. normal operation. If not OK, REFER
to the Wiring Diagrams manual to
identify the possible causes of the
circuit short.

CA2 CHECK THE COMPASS MODULE GROUND
CIRCUIT FOR AN OPEN
Yes
• If not equipped with a camera display mirror, measure GO to CA3 .
the voltage between the auto-dimming interior mirror
C911-1, circuit CBP41 (BU), harness side and No
auto-dimming interior mirror C911-4, circuit GD139 REPAIR circuit GD133 (BK) for an
(BK/YE), harness side and ground. open. CLEAR the DTCs. REPEAT the
self-test.
PINPOINT TEST CA: THE COMPASS IS INOPERATIVE 5336

• If equipped with a camera display mirror, measure the

voltage between the auto-dimming interior mirror
C9039-1, circuit CBP41 (BU), harness side and
auto-dimming interior mirror C9039-3, circuit GD139
(BK/YE), harness side and ground.

CA3 CHECK THE COMPASS COMMUNICATION
Yes
• Ignition OFF. REPAIR the circuit in question for a
• Disconnect: IPC C220. short to voltage. CLEAR the DTCs.
• Measure the voltage between the auto-dimming interior
mirror C911-9 or C9039-9 (camera display mirror), No
circuit VMC31 (GY/BU), harness side and ground; and GO to CA4 .
between the auto-dimming interior mirror C911-10 or
C9039-10 (camera display mirror), circuit VMC30
(BU/GY), harness side and ground.

PLUS (+) CIRCUIT FOR AN OPEN AND SHORT TO
GROUND


• Measure the resistance between the IPC C220-23, circuit GO to CA5 .
VMC30 (BU/GY), harness side and the auto-dimming
interior mirror C911-10 or C9039-10 (camera display No
mirror), VMC30 (BU/GY), harness side; and between REPAIR the circuit for an open or
the IPC C220-23, circuit VMC30 (BU/GY), harness side short to ground. CLEAR the DTCs.
and ground. REPEAT the self-test.
• Is the resistance less than 5 ohms between the IPC

and the auto-dimming interior mirror, and greater
than 10,000 ohms between the IPC and ground?
MINUS (-) CIRCUIT FOR AN OPEN AND SHORT TO
GROUND
Yes
• Ignition OFF. GO to CA6 .
• Measure the resistance between the IPC C220-24, circuit
VMC31 (GY/BU), harness side and the auto-dimming No
interior mirror C911-9 or C9039-9 (camera display REPAIR the circuit for an open or
mirror), VMC31 (GY/BU), harness side; and between short to ground. CLEAR the DTCs.
the IPC C220-24, circuit VMC31 (GY/BU), harness side REPEAT the self-test.
and ground.
• Is the resistance less than 5 ohms between the IPC

and the auto-dimming interior mirror, and greater
than 10,000 ohms between the IPC and ground?
CA6 CHECK FOR CORRECT IPC OPERATION
Yes
♦ pushed-out pins
correctly. The system is operating correctly at
this time. The concern may have been

present. connector.
Pinpoint Test CB: The Compass Is Inaccurate
NOTE: This procedure is only applicable to vehicles without navigation. For vehicles with navigation, there
is no compass zone adjustment.
Normal Operation
The compass module (integral to the auto-dimming interior mirror) provides vehicle directional inputs over
the communication circuits to the Instrument Panel Cluster (IPC), which sends the compass information to the
Front Display Interface Module (FDIM) (compass display) over the Medium Speed Controller Area Network
(MS-CAN). The FDIM displays the compass direction according to the information that has been provided by
the compass module to the IPC . The compass display may provide inaccurate readings only if there is a
concern with the compass module or the compass zone setting is incorrect or the compass is out of calibration.
• Compass zone setting

• Compass calibration
• Compass module (integral to the auto-dimming interior mirror)
PINPOINT TEST CB: THE COMPASS IS INACCURATE
NOTE: Always set the zone and calibrate the compass before replacing an inaccurate compass.

CB1 CHECK THE
COMPASS ACCURACY
Yes
• Position the vehicle The compass is OK. The concern may have been caused by an incorrect
and observe the zone setting, or the compass was out of calibration.
compass display as
follows: No
INSTALL a new compass module. REFER to Auto-Dimming Interior
Mirror in Section 501-09 . SET the zone. REFER to Compass Zone
Adjustment in this section. CALIBRATE the compass. REFER to
Compass Calibration in this section. TEST the system for normal
Compass operation.
Direction Display
North N
Northeast NE
East E
Southeast SE

South S
Southwest SW
West W
Northwest NW
• Does the compass

display as indicated?
PINPOINT TEST CB: THE COMPASS IS INACCURATE 5340

Message Center Configuration
Oil Life Reset - Non-Hybrid
NOTE: The oil life calculation is set at a maximum of approximately 12,070 km (7,500 miles) or 180 days
(non-hybrid) or 16,093 km (10,000 miles) (hybrid).
1. Press and release the SETUP button 2 times to display OIL LIFE XXX% HOLD RESET = NEW.
2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%.
Oil Life Start Value - Non-Hybrid
NOTE: The oil life start value is used to reset the oil life value back to the maximum of approximately 12,070
km (7,500 miles) or 180 days if the value was previously changed, or to lower the value from the maximum
(12,070 km [7,500 miles] or 180 days) in 10% increments down to 10%.
1. Press and release the SETUP button 2 times to display OIL LIFE = XXX% HOLD RESET = NEW.
2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%.
3. Release the RESET button then press and release the RESET button to lower the percentage by 10%
(down to 10%) for each button press or return the value to 100%.
Oil Life Reset And Oil Life Start Value - Hybrid
NOTE: The oil life calculation is set at a maximum of approximately 16,093 km (10,000 miles) or 12 months.
NOTE: The message center is displayed on the LH side of the speedometer and is split into several different
viewing panes.
1. Press and release the SETUP button to display VEHICLE SETTINGS in the LH viewing pane of the
message center.
2. Press and release the RESET button to display the next viewing pane.
3. Press and release the SETUP button to select and highlight OIL LIFE in the LH viewing pane of the
message center.>
4. NOTE: Once the RESET button is pressed, the message center highlights the currently selected oil
life start value. This value can be changed or left as currently selected.
Press and release the RESET button to display the move to the RH viewing pane of the message
center and highlight SET TO xxx%.
5. Press and release the SETUP button to highlight the desired oil life start value.
Message Center Configuration 5341

6. NOTE: A pop-up window appears stating HOLD RESET FOR 2 SECONDS TO CONFIRM. PRESS
INFO TO CANCEL.
Press and release the RESET button.
7. Press and hold the RESET button for approximately 2 seconds to select and confirm the desired oil
life start value.
Message Center Configuration 5342

Belt-Minder® Deactivating/Activating
Preration
NOTE: The driver and front passenger Belt-Minder® are deactivated/activated independently. When
deactivating/activating one seating position, do not buckle the other position as this terminates the process.
1. Before deactivating/activating the Belt-Minder®, set the parking brake.
2. On automatic transaxles, place the selector lever in PARK (P).
3. On manual transaxles, place the shifter in NEUTRAL (N).
4. Place the ignition in the OFF mode.
5. Unbuckle the driver and front passenger safety belts.
Deactivating/Activating
1. Place the ignition in the RUN mode (do not start the engine).
2. Wait approximately 1 minute until the safety belt warning indicator turns off.
3. NOTE: Step 3 must be completed within 30 seconds after the safety belt warning indicator turns off.
To disable the seating position, buckle then unbuckle the safety belt 3 times, ending in the unbuckled
state.
• After Step 3, the safety belt warning indicator illuminates for 3 seconds.
4. Within 10 seconds of the safety belt warning indicator turning on, buckle then unbuckle the safety
belt. This enables the Belt-Minder® if disabled and disables the Belt-Minder® if enabled.
• This disables the Belt-Minder® feature for that seating position, if it is currently enabled. As
confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds.
• This enables the Belt-Minder® feature for that seating position, if it is currently disabled. As
confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds,
followed by 3 seconds with the light off followed by the safety belt warning indicator flashing
4 times per second for 3 seconds again.
5. The safety belt warning indicator flashing 4 times per second for 3 seconds provides confirmation that
the Belt-Minder® is disabled.
6. The following sequence of events confirms the Belt-Minder® is enabled:

• flashing of the safety belt warning indicator 4 times per second for 3 seconds
• 3 seconds with the safety belt warning indicator off
• flashing of the safety belt warning indicator 4 times per second for 3 seconds again
7. After confirmation, the deactivation/activation procedure is complete.
Belt-Minder® Deactivating/Activating 5343

Belt-Minder® Deactivating/Activating 5344

Compass Zone Adjustment
NOTE: This procedure is only applicable to vehicles without navigation.
1. Refer to the compass calibration zone map to select the correct compass zone setting for the
geographic location of the vehicle.
2. With the ignition in the ON position, press and hold the Front Controls Interface Module (FCIM)
(Fusion/Milan) or Front Display Interface Module (FDIM) (MKZ) 7 and 9 buttons (for approximately
5 seconds) until the compass display shows the current zone setting (ZONE XX). Release the 7 and 9
buttons.
3. NOTE: After the 7 and 9 buttons have been released for approximately 5 seconds, the compass
display exits the zone setting mode.
Before the zone setting mode turns off (within 5 seconds), momentarily press and release the 7 and 9
buttons to increase the zone increment by one. Set the zone display number to match the vehicle
geographical location on the compass calibration zone map.
4. Release the 7 and 9 buttons for 5 seconds to exit the zone setting mode.
Compass Zone Adjustment 5345

Compass Zone Adjustment 5346

Compass Calibration
NOTE: This procedure is only applicable to vehicles without navigation.
1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or
structures. Switch off all non-essential electrical accessories (heated rear window, heater fan, A/C,
map lamps, and wipers) and make sure all doors are closed.
Start the vehicle.
2. NOTE: The vehicle remains in the CAL mode until the compass has been successfully calibrated.
NOTE: While holding the Front Controls Interface Module (FCIM) (Fusion/Milan) or Front Display
Interface Module (FDIM) (MKZ) 7 and 9 buttons down, the compass display first enters the ZONE
setting mode (after 5 seconds) and then after another 5 seconds (10 seconds total), the compass
display enters the CAL mode.
Press and hold (for approximately 10 seconds) the 7 and 9 buttons until the CAL indicator appears in
the display, then release the buttons.
3. NOTE: If the CAL indicator does not turn off after the vehicle is driven in a circle at least 5 times,
repeat the procedure.
Drive the vehicle slowly at less than 5 km/h (3 mph) in a continuous circle until the CAL indicator
disappears from the display and the compass heading is shown.
4. If the CAL indicator does not turn off after driving in a circle at least 5 times (and the procedure has
been repeated at least once), install a new compass module (integral to the auto-dimming interior
mirror). For additional information, refer to Auto-Dimming Interior Mirror in Section 501-09 .
Compass Calibration 5347

Compass Calibration 5348

SECTION 413-01: Instrumentation, Message Center, and 2012 Fusion, MKZ, Fusion Hybrid, MKZ
Warning Chimes Hybrid Workshop Manual
NOTE: Fusion shown, other vehicles similar.

1 W707628 Screws (3 required)
2 10849 Instrument Panel Cluster (IPC)
3 - Electrical connector (part of 14401)
Removal
NOTE: If installing a new Instrument Panel Cluster (IPC), all vehicle keys are erased during the parameter
reset procedure. Verify at least 2 of the vehicle keys are available prior to carrying out this procedure.
1. If installing a new IPC , upload the module configuration to the scan tool. For additional information,
refer to Section 418-01 , Programmable Module Installation (PMI).
2. Remove the IPC finish panel. For additional information, refer to Section 501-12 .
3. Remove the 3 screws and the IPC .

• Disconnect the electrical connector.
Installation
1. Position the IPC in the instrument panel and connect the electrical connector.
2. Install the 3 screws.
3. Install the IPC finish panel. Refer to Section 501-12 .
4. NOTE: If a new IPC is installed, updated, or re-configured, the IPC and the PCM (non-hybrid) or
Transmission Control Module (TCM) (hybrid) require a parameter reset to allow the IPC and the
PCM or TCM to recognize each other. Failure to carry out the parameter reset to the IPC and the
PCM or TCM can result in a no start condition.

If a new IPC was installed, updated or reconfigured, carry out the parameter reset procedure. For
additional information, refer to Section 419-01B (non-hybrid) or Section 419-01C (hybrid).
5. NOTE: The vehicles integrated keys (or standard Passive Anti-Theft System (PATS) keys) must be
programmed to the new IPC .
If a new IPC was installed, program the integrated keys. For additional information, refer to Section
419-01B (non-hybrid) or Section 419-01C (hybrid).
6. If a new IPC was installed, download the IPC configuration information from the scan tool into the
new IPC . For additional information, refer to Section 418-01 , PMI .

SECTION 413-06: Horn 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual
Horn bolt 10 89


SECTION 413-06: Horn
Manual
Horn
The horn system consists of the following components:
• Horn switches (part of the steering wheel)

• Clockspring
• Horn relay (part of the SJB )
• Horn
The horn can be operated by pressing the switch on the steering wheel. It is also controlled by the SJB when it
is utilized for the panic function, or during a perimeter anti-theft alarm event.
Horn Location
The horn is mounted on the RH side of the front subframe in the RH wheel well behind the front fender splash
shield.
Horn 5352
SECTION 413-06: Horn 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual
Horn
Special Tool(s)


Flex Probe Kit
The SJB supplies the control and switched voltage to the horn relay (part of the SJB ). When the driver air bag
is pressed, ground is supplied through the steering wheel to the horn relay. The horn relay is then energized,
directing voltage to the horn and enabling the horn to sound.
The horn switch is comprised of 2 sets of contacts separated by springs. The lower set is connected to ground
and the upper set is connected to the horn signal circuit. When the driver air bag module is pressed, it pushes
down on the upper set of contacts, collapsing the springs and allowing the contacts to touch. When the
contacts touch, it completes the circuit.
The SJB provides ground to the horn relay control side to sound the horn when the vehicle security system is
armed, an intrusion is detected, or the panic alarm is activated.
• Horn • Smart Junction Box (SJB) fuse 24

• Steering wheel harness (20A)
Horn 5353
• Horn switches (part of the steering • Clockspring

wheel) • SJB



418-00 .
• If the network test passes, verify the symptom. GO to Symptom Chart .
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: The Horn Is Inoperative
Refer to Wiring Diagrams Cell 44 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Horn/Cigar Lighter for
Normal Operation
The Smart Junction Box (SJB) supplies the switched and control voltage to the horn relay (part of the SJB ).
When the horn switches (part of the steering wheel) are pressed, the switches are grounded to the steering
wheel. Ground is then supplied to the horn relay, energizing the horn relay. The horn relay then sends voltage
to the horn, enabling the horn to sound. The horn assembly has its own ground.

• Fuse
• Horn
• Clockspring
• SJB
PINPOINT TEST A: THE HORN IS INOPERATIVE

A1 CHECK THE SJB OUTPUT
Yes
• Ignition ON. GO to A2 .
DataLogger. No
• Select the SJB horn PID (HORN). Active command the horn on and VERIFY the SJB fuse 24
then off. (20A) is OK. If OK, GO to
• Does the horn sound when commanded on? A6 . If not OK, REFER to
the Wiring Diagrams
Manual to identify the
possible causes of the
circuit short.
A2 CHECK FOR VOLTAGE TO THE CLOCKSPRING
Yes
• Connect: Negative Battery Cable. GO to A4 .
• Measure the voltage between the clockspring C218a-8, circuit
CRH02 (BU/WH), harness side and ground. No
GO to A3 .

A3 CHECK THE HORN RELAY COIL GROUND CONTROL
CIRCUIT FOR AN OPEN
Yes
• Disconnect: SJB C2280b. GO to A9 .
• Measure the resistance between the SJB C2280b-41, circuit CRH02
(BU/WH), harness side and the clockspring C218a-8, circuit CRH02 No
(BU/WH), harness side. REPAIR circuit CRH02
(BU/WH) for an open.
REPOWER the SRS .
PINPOINT TEST A: THE HORN IS INOPERATIVE 5355

REFER to Section
501-20B . TEST the
system for normal
operation.

A4 CHECK THE STEERING WHEEL HARNESS FOR AN OPEN
Yes
• Disconnect: Horn Switch C2996 and C2997. GO to A5 .
• Measure the resistance between the upper clockspring C218b-1,
circuit CRH02 (BU/WH), harness side and the horn switch No
C2996-1, circuit CRH02 (BU/WH), harness side; and between the REPAIR circuit CRH02
upper clockspring C218b-1, circuit CRH02 (BU/WH), harness side (BU/WH) for an open.
and the horn switch C2997-1, circuit CRH02 (BU/WH), harness INSTALL the driver air
side. bag module. REFER to
Section 501-20B . TEST
operation.

A5 CHECK THE CLOCKSPRING FOR AN OPEN
Yes
• Measure the resistance between the clockspring C218a pin 8, INSTALL a new steering
component side and the clockspring C218b pin 1, component side. wheel. REFER to Section
211-04 . TEST the system
No
INSTALL a new
clockspring. REFER to
Section 501-20B . TEST
operation.
A6 CHECK FOR VOLTAGE TO THE HORN
Yes
• Disconnect: Horn C131. GO to A7 .
• While pressing the horn switch, measure the voltage between the
horn C131-2, circuit SRH01 (YE/RD), harness side and ground. No
GO to A8 .


A7 CHECK FOR VOLTAGE TO THE HORN USING THE
CONNECTOR GROUND
Yes
• While pressing the horn switch, measure the voltage between the INSTALL a new horn.
horn C131-2, circuit SRH01 (YE/RD), harness side and the horn REFER to Horn in this
C131-1, circuit GD123 (BK/GY), harness side. section. TEST the system
No
(BK/GY) for an open.
TEST the system for
normal operation.

A8 CHECK THE HORN VOLTAGE SUPPLY CIRCUIT FOR AN
OPEN
Yes
• Disconnect: SJB C2280e. GO to A9 .
• Measure the resistance between the SJB C2280e-5, circuit SRH01
(YE/RD), harness side and the horn C131-2, circuit SRH01 No
(YE/RD), harness side. REPAIR circuit SRH01
(YE/RD) for an open.
TEST the system for
normal operation.

Yes
• Disconnect all the SJB connectors. INSTALL a new SJB .
• Check for: REFER to Section 419-10 .
♦ corrosion REPOWER the SRS .
♦ damaged pins REFER to Section
♦ pushed-out pins 501-20B . TEST the
• Connect all the SJB connectors and make sure they seat correctly. system for normal
• Operate the system and verify the concern is still present. operation.
No
The system is operating

correctly at this time. The

caused by a loose or
corroded connector.
REPOWER the SRS .
REFER to Section
501-20B .
Pinpoint Test B: The Horn Is Always On
Refer to Wiring Diagrams Cell 44 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Horn/Cigar Lighter for
Normal Operation
The Smart Junction Box (SJB) supplies the switched and control voltage to the horn relay (part of the SJB ).
When the horn switches (part of the steering wheel) are pressed, the switches are grounded to the steering
wheel. Ground is then supplied to the horn relay, energizing the horn relay. The horn relay then sends voltage
to the horn, enabling the horn to sound.

• Clockspring
• SJB
PINPOINT TEST B: THE HORN IS ALWAYS ON

B1 CHECK THE HORN POWER SUPPLY
Yes
• Ignition OFF. REPAIR circuit SRH01 (YE/RD) for a short to
• Disconnect: SJB C2280e. voltage. TEST the system for normal operation.
• Does the horn continue to sound?
No
GO to B2 .
B2 CHECK THE HORN SWITCH INPUT
Yes
• Disconnect: SJB C2280b. GO to B6 .
• Connect: SJB C2280e.
• Does the horn continue to sound? No
GO to B3 .
B3 CHECK THE HORN RELAY COIL
GROUND CONTROLLED CIRCUIT FOR A
SHORT TO GROUND

• Depower the Supplemental Restraint System Yes

(SRS). Refer to Section 501-20B . GO to B4 .
• Disconnect: Clockspring C218a.
• Measure the resistance between the No
clockspring C218a-8, circuit CRH02 REPAIR circuit CRH02 (BU/WH) for a short to
(BU/WH), harness side and ground. ground. REPOWER the SRS . REFER to Section
501-20B . TEST the system for normal operation.

ohms?
B4 CHECK THE CLOCKSPRING FOR A
SHORT TO GROUND
Yes
• Remove the driver air bag module. Refer to GO to B5 .
Section 501-20B .
• Connect: Clockspring C218a. No
• Disconnect: Upper Clockspring C218b. INSTALL a new clockspring. REFER to Section
• Measure the resistance between the SJB 501-20B . TEST the system for normal operation.
C2280b-41, circuit CRH02 (BU/WH),

ohms?
B5 CHECK THE STEERING WHEEL
HARNESS FOR A SHORT TO GROUND
Yes
• Disconnect: Horn Switch C2996 and C2997. INSTALL a new steering wheel. REFER to
• Measure the resistance between the upper Section 211-04 . TEST the system for normal
clockspring 218b-1, circuit CRH02 operation.
(BU/WH), harness side and ground.
No
REPAIR or INSTALL a new steering wheel
harness. INSTALL the driver air bag module.
REFER to Section 501-20B . TEST the system for
normal operation.
PINPOINT TEST B: THE HORN IS ALWAYS ON 5359


ohms?
B6 CHECK FOR CORRECT SJB
OPERATION
Yes
• Disconnect all the SJB connectors. INSTALL a new SJB . REFER to Section 419-10 .
• Check for: TEST the system for normal operation.
♦ corrosion
♦ damaged pins No
sure they seat correctly. corroded connector.
still present.
PINPOINT TEST B: THE HORN IS ALWAYS ON 5360


Manual
REMOVAL AND
INSTALLATION
Horn

1 W706805 RH front fender splash shield screws (4 required)
2 - Horn electrical connector (part of 14290)
3 W605784 Horn bolt
4 13832 Horn
100-02 .
2. Remove the 4 RH front fender splash shield screws.

• Pull the RH front fender splash shield downward to access the horn.
4. Remove the bolt and the horn.

Horn 5361
Horn 5362
SECTION 413-13: Parking Aid 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual
Item Specification
Azimuth system check object position 1 (P1) and position 3 (P3) distance from sensor 30 cm (12 in) rear
Azimuth system check object position 2 (P2) distance from sensor 152 cm (60 in) rear
Horn 5363

SECTION 413-13: Parking Aid
Manual
Parking Aid
The parking aid system consists of:
• Parking aid sensors (located in the rear bumper cover)

• Parking Aid Module (PAM) (located behind the LH rear seat trim panel)
• Parking aid speaker (located under the left side of the parcel shelf)
• Parking aid disable feature (integral to the Instrument Panel Cluster (IPC) message center)
The parking aid system calculates the distance to an object around the rear of the vehicle by the use of 3
ultrasonic sensors. The parking aid system detects objects behind the vehicle when the REVERSE (R) gear is
selected.
Video (If Equipped)
The rear video camera system consists of the following:
• Video camera located in:

♦ the license lamp housing (Fusion)
♦ the luggage compartment lid (MKZ)
• Auto-dimming interior mirror (without navigation)
• Front Display Interface Module (FDIM) (with navigation)
The video camera is activated when REVERSE (R) is selected. The image from the rear video camera is
displayed in the LH side of the auto-dimming interior mirror (without navigation) or the FDIM (with
navigation).
Parking Aid 5364

Parking Aid
Special Tool(s)


Flex Probe Kit
The parking aid sensors detect objects approximately 152 cm (60 in) from the rear of the vehicle, 50 cm (1.6
ft) from the rear side of the vehicle, and 30 cm (12 in) above the ground. The Parking Aid Module (PAM)
calculates the distance to an object within the 170 degree semicircular area around the rear of the vehicle. A
variable warning tone is generated from a parking aid speaker. The parking aid speaker increases its warning
tone rate as the vehicle gets closer to an obstacle. When an object is detected within 25 cm (10 in) of the
sensors, the warning tone becomes continuous.
The parking aid speaker has a dual function for vehicles equipped with the parking aid system and cross
traffic alert system. The parking aid speaker will emit an audible warning tone to notify the driver of impeding
traffic from the side of the vehicle when backing out of parking spaces. Refer to Section 419-04 for cross
traffic alert information.
The parking aid system is enabled when the ignition switch is in the RUN position and the REVERSE (R)
gear is selected. The parking aid system is disabled if a fault is detected in 1 of the 3 sensors, the parking aid
speaker, or the PAM . This is indicated by a warning and the message center will display the message
"CHECK PARK AID".
The PAM is on the Medium Speed Controller Area Network (MS-CAN) and can be diagnosed with a scan
tool. The PAM communicates with the scan tool, the Audio Control Module (ACM), the SOD-L , the SOD-R
and the Instrument Panel Cluster (IPC). The following chart describes network messages used by the PAM :
NOTE: Both the MS-CAN and the High Speed Controller Area Network (HS-CAN) are used for intermodule
communication. A gateway message is transferred from one network to another network through the IPC .
Refer to Section 418-00 for network communication information.
PAM Network Communication Messages
Parking Aid 5365

Broadcast Message Originating Module Network Type Receiving Module

Ignition switch position IPC MS-CAN PAM
Parking aid sounder volume cutback request PAM MS-CAN ACM
Parking aid enabled status IPC MS-CAN PAM
Parking aid system status PAM MS-CAN IPC
Transmission selector (PRNDL) range (gateway) IPC MS-CAN PAM
Side obstacle detection cross traffic alert SOD-L and SOD-R MS-CAN PAM
Vehicle speed (gateway) IPC MS-CAN PAM
Electrical
• Smart Junction Box (SJB) fuse 35
(10A)
• Parking aid sensors



418-00 .
8. Clear the continuous DTCs and carry out the self-test diagnostics for the PAM .
Parking Aid 5366

9. NOTE: Follow the non-network DTC diagnostics (B-codes, C-codes, P-codes) prior to the network
DTC diagnostics (U-codes).
If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to the
PID Chart
PID Description
IGN_V Ignition voltage
LRO_DIST Left rear outer sensor distance to object
RC_DIST Rear center sensor distance to object
RRO_DIST Right rear outer sensor distance to object
LRO_ATTEN Left rear outer sensor attenuation
RC_ATTEN Rear center sensor attenuation
RRO_ATTEN Right rear outer sensor attenuation
TRANSGR Transmission gear position
DTC Charts
Parking Aid Module (PAM) DTC Chart

B1299 Power Supply Sensor Circuit GO to Pinpoint Test E .
Short to Ground
B1342 ECU is Faulted CLEAR the DTCs. REPEAT the Parking Aid Module (PAM)
self-test. If DTC B1342 is retrieved again, INSTALL a new PAM .
REFER to Parking Aid Module (PAM) in this section. CLEAR all
DTCs. Test the system for normal operation.
B2477 Module Configuration Failure The PAM is not configured. REFER to Section 418-01
Programmable Module Installation (PMI) to configure the PAM .
CLEAR all DTCs. Test the system for normal operation.
C1699 Left Rear Sensor Circuit Short GO to Pinpoint Test C .
to Vbat
C1700 Left Rear Sensor Circuit GO to Pinpoint Test B .
Failure or Blockage
C1701 Left Rear Sensor Circuit Fault GO to Pinpoint Test D .
C1702 Right Rear Sensor Circuit GO to Pinpoint Test C .
Short to Vbatt
C1703 Right Rear Sensor Circuit GO to Pinpoint Test B .
Failure or Blockage
C1704 Right Rear Sensor Circuit GO to Pinpoint Test D .
Fault
C1705 GO to Pinpoint Test C .
Parking Aid 5367

Rear Center Sensor Circuit

Short to Vbat
C1706 Rear Center Sensor Circuit GO to Pinpoint Test B .
Failure
C1707 Rear Center Sensor Circuit GO to Pinpoint Test D .
Fault
C1742 Rear Sounder Circuit Failure GO to Pinpoint Test F .
C1743 Rear Sounder Circuit Short to GO to Pinpoint Test F .
Vbat
U0140 Lost Communication With GO to Pinpoint Test G .
Body Control Module ( GEM )
U0155 Lost Communication With GO to Pinpoint Test H .
Instrument Panel Cluster ( IPC
) Control Module
U2051 One or More Calibration Files The PAM calibration data is corrupt or the module is not calibrated.
Missing/Corrupt REFER to Section 418-01 Programmable Module Installation (PMI)
to configure the PAM . CLEAR all DTCs. Test the system for normal
operation.
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: The Parking Aid Is Inoperative/Does Not Operate Correctly
Normal Operation
The parking aid system is enabled when the ignition switch is in the RUN position and the REVERSE (R)
gear is selected. The Parking Aid Module (PAM) receives a reverse gear input from the Instrument Panel
Cluster (IPC) through the Medium Speed Controller Area Network (MS-CAN). A reference voltage and
signal return is supplied to the parking aid sensors from the PAM . The PAM receives an input signal from
each individual parking aid sensor. The system can be disabled through the message center which is part of
the IPC .

• Parking aid sensors alignment
• Parking aid sensors
• PAM
• Rear bumper cover

PINPOINT TEST A: THE PARKING AID IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

A1 CHECK THE DTCs FROM BOTH THE
CONTINUOUS AND ON-DEMAND PAM
SELF-TESTS
Yes
• Check the PAM DTCs from the continuous REFER to DTC Charts in this section.
• Are any PAM DTCs recorded? No
GO to A2 .
A2 CHECK THE MESSAGE CENTER FOR
PARKING AID DISABLE OPERATION
Yes
• While observing the IPC message center, GO to A3 .
disable and enable the parking aid system.
• Does the message center display PARK No
AID OFF when the parking aid system is REFER to Section 413-01 .
disabled, and display PARK AID ON
when the parking aid system is enabled?
A3 CHECK FOR CORRECT REVERSE
GEAR INPUT
Yes
• Apply the parking brake. GO to A4 .
• Ignition ON.
• Select REVERSE. No
scan tool: PAM DataLogger.
• Monitor the PAM PID (TRANSGR).
• Does the PID read REVERSE?
A4 CHECK THE PARKING AID SENSORS
FOR CORRECT ALIGNMENT
Yes
NOTE: If the vehicle was in a rear end GO to A6 .
collision, the parking aid sensors may not be
aligned correctly. No
REALIGN or INSTALL a new bumper cover.
• Check the bumper for correct alignment. REFER to Section 501-19 . If the vehicle was in a
• Carry out the azimuth system check. Refer rear end collision, further body work may be
to Azimuth System Check in this section. required to bring the parking aid sensors into
• Carry out the elevation system check. Refer correct alignment.
to Elevation System Check in this section.
• Does the parking aid system pass both
system checks?
A5 CHECK THE PCM FOR DIGITAL TR
SENSOR DTCs
Yes
• Check the PCM for DTCs P0705, P0706, REFER to Section 307-01A , Section 307-01B , or
P0708 and P0709. Section 307-01C to continue diagnosis of the
PINPOINT TEST A: THE PARKING AID IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

5369
• Are any of these DTCs present? digital TR sensor.
No
GO to A7 .
A6 MONITOR THE PAM DISTANCE PIDs
Yes
scan tool: PAM DataLogger.
• Monitor the PAM distance PIDs while No
moving a test object into and out of the INSTALL a new sensor(s) for the one in question.
azimuth field directly behind each of the REFER to Parking Aid Sensor in this section.
rear sensors: TEST the system for normal operation.
PID Description
LRO_DIST Left rear outer parking aid
sensor distance
RC_DIST Rear center parking aid sensor
distance
RRO_DIST Right rear outer parking aid
sensor distance
• Do the PID readings correspond to the

approximate distance between sensor and
test object?
A7 CHECK FOR CORRECT PAM
OPERATION
Yes
• Disconnect the PAM connector. INSTALL a new PAM . REFER to Parking Aid
• Check for: Module (PAM) in this section. TEST the system
♦ damaged pins
• Connect the PAM connector and make sure The system is operating correctly at this time. The
it seats correctly. concern may have been caused by a loose or
• Operate the system and determine if the corroded connector.
Pinpoint Test B: DTCs C1700, C1703 And C1706
Refer to Wiring Diagrams Cell 131 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Parking Aid for schematic
and connector information.
Normal Operation
The Parking Aid Module (PAM) supplies a reference voltage and signal return to the parking aid sensors.
Each of the parking aid sensors has an individual input signal to the PAM . When an object is present behind
the vehicle, the PAM receives an input signal from the sensors and determines the distance of the object to the

vehicle. A fault condition occurs when the PAM detects an open in the parking aid sensor circuits or the
parking aid sensor input signal is shorted to ground.
• DTC C1700 (Left Rear Sensor Circuit Failure or Blockage) - a continuous and on-demand DTC that
sets when any of the left rear parking aid sensor circuits are open or the sensor signal line is shorted to
ground.
• DTC C1703 (Right Rear Sensor Circuit Failure or Blockage) - a continuous and on-demand DTC that
sets when any of the right rear parking aid sensor circuits are open or the sensor signal line is shorted
to ground.
• DTC C1706 (Rear Center Sensor Circuit Failure) - a continuous and on-demand DTC that sets when
any of the rear center parking aid sensor circuits are open or the sensor signal line is shorted to
ground.

• Parking aid sensor(s)
• Parking aid bumper harness
• PAM
PINPOINT TEST B: DTCs C1700, C1703 AND C1706

B1 RETRIEVE THE DTCs FROM THE PAM SELF-TEST
Yes
• Check the PAM DTCs from the continuous and on-demand GO to B2 .
self-tests.
• Are multiple DTCs recorded? No
For DTC C1700, C1703 or C1706
GO to B3 .

B2 CHECK THE BUMPER WIRING HARNESS
Yes
• Inspect the bumper wiring harness for opens, shorts, GO to B3 .
grounds, or corrosion.
• Is the bumper wiring harness OK? No
REPAIR or INSTALL a new
bumper wiring harness. CLEAR the
operation.
B3 CHECK THE SENSOR CIRCUITRY FOR OPENS
PINPOINT TEST B: DTCs C1700, C1703 AND C1706 5371


• Disconnect: Suspect Parking Aid Sensor C4009, C4011 or GO to B4 .
C4228.
• Disconnect: PAM C4014. No
• Measure the resistance between the PAM C4014, harness REPAIR the circuit in question.
side and the suspect parking aid sensor, harness side as CLEAR the DTCs. TEST the
follows: system for normal operation.
PAM Sensor
Rear Connector- Connector-
DTC Sensor Pin Pin Circuit
C1700 LH C4014-9 C4009-1 LMP07
outer (BU/WH)
C1700 LH C4014-15 C4009-2 VMP15
outer (YE/GN)
C1700 LH C4014-12 C4009-3 RMP07
outer (GN/WH)
C1703 RH C4014-9 C4011-1 LMP07
outer (BU/WH)
C1703 RH C4014-16 C4011-2 VMP17
outer (YE/OG)
C1703 RH C4014-12 C4011-3 RMP07
outer (GN/WH)
C1706 Center C4014-9 C4228-1 LMP07
(BU/WH)
C1706 Center C4014-14 C4228-2 VMP14
(WH/OG)
C1706 Center C4014-12 C4228-3 RMP07
(GN/WH)

B4 CHECK THE SENSOR CIRCUITRY FOR SHORTS TO
GROUND
Yes
• Measure the resistance between the suspect parking aid If all of the parking aid sensors
sensor, harness side and ground as follows: recorded DTCs, GO to B5 .
If one or more parking aid sensor(s)

recorded DTCs, INSTALL a new
sensor(s) for the one in question.
PINPOINT TEST B: DTCs C1700, C1703 AND C1706 5372

DTC Rear Sensor Connector-Pin Circuit REFER to Parking Aid Sensor in

C1700 LH outer C4009-2 VMP15 (YE/GN) this section. CLEAR the DTCs.
C1703 RH outer C4011-2 VMP17 (YE/OG) operation.
C1706 Center C4228-2 VMP14 (WH/OG)
No
CLEAR the DTCs. TEST the

B5 CHECK FOR CORRECT PAM OPERATION
Yes
• Disconnect the PAM connector. INSTALL a new PAM . REFER to
• Check for: Parking Aid Module (PAM) in this
♦ corrosion section. TEST the system for
♦ pushed-out pins
• Connect the PAM connector and make sure it seats No
• Operate the system and determine if the concern is still this time. The concern may have
present. been caused by a loose or corroded
Pinpoint Test C: DTCs C1699, C1702 And C1705
Normal Operation
vehicle. A fault condition occurs when the PAM detects a short to voltage on the parking aid sensor signal
circuit.
• DTC C1699 (Left Rear Sensor Circuit Short to Vbat) - a continuous and on-demand DTC that sets
when the left rear parking aid sensor signal line is shorted to voltage.
• DTC C1702 (Right Rear Sensor Circuit Short to Vbat) - a continuous and on-demand DTC that sets
when the right rear parking aid sensor signal line is shorted to voltage.
• DTC C1705 (Rear Center Sensor Circuit Short to Vbat) - a continuous and on-demand DTC that sets
when the left rear center parking aid sensor signal line is shorted to voltage.

• PAM
PINPOINT TEST C: DTCs C1699, C1702 AND C1705

C1 RETRIEVE THE DTCs FROM THE PAM
SELF-TESTS
Yes
• Check the PAM DTCs from the continuous GO to C2 .
• Are multiple DTCs recorded? No
For DTC C1699, C1702 or C1705 GO to C3 .
For all other DTCs, REFER to DTC Charts in this

section.
C2 CHECK THE BUMPER WIRING
HARNESS
Yes
• Inspect the bumper wiring harness for GO to C3 .
opens, shorts, grounds, or corrosion.
REPAIR or INSTALL a new bumper wiring
harness. CLEAR the DTCs. TEST the system for
normal operation.
C3 CHECK THE SENSOR CIRCUITRY FOR
SHORTS TO VOLTAGE
Yes
• Ignition OFF. REPAIR the circuit in question. CLEAR the DTCs.
• Disconnect: Suspect Parking Aid Sensor TEST the system for normal operation.
C4009, C4011 or C4228.
• Disconnect: PAM C4014. No
• Ignition ON. GO to C4 .
• Measure the voltage between the suspect
parking aid sensor, harness side and ground
as follows:
Rear
DTC Sensor Connector-Pin Circuit
C1699 LH C4009-2 VMP15
outer (YE/GN)
C1702 RH C4011-2 VMP17
outer (YE/OG)
PINPOINT TEST C: DTCs C1699, C1702 AND C1705 5374

C1705 LH C4228-2 VMP14

inner (WH/OG)

C4 CHECK THE PARKING AID SENSORS
Yes
• Install a known good parking aid sensor(s) If all of the parking aid sensors recorded DTCs, GO
for each of the suspect parking aid to C5 .
sensor(s).
• Clear the DTCs. Repeat the self-test. If one or more parking aid sensor(s) recorded
• Test the system for normal operation. DTCs, INSTALL a new sensor(s) for the one in
• Is the concern still present? question. REFER to Parking Aid Sensor in this
section. CLEAR the DTCs. TEST the system for
normal operation.
No
REPAIR the circuit in question. CLEAR the DTCs.
C5 CHECK FOR CORRECT PAM
OPERATION
Yes
• Disconnect the PAM connector. INSTALL a new PAM . REFER to Parking Aid
• Check for: Module (PAM) in this section. TEST the system for
♦ damaged pins
• Connect the PAM connector and make sure The system is operating correctly at this time. The
it seats correctly. concern may have been caused by a loose or
• Operate the system and determine if the corroded connector. CLEAR the DTCs. REPEAT
concern is still present. the self-test.
Pinpoint Test D: DTCs C1701, C1704 And C1707
Normal Operation
vehicle. A fault condition occurs when the PAM detects an open in the parking aid sensor circuits or the
parking aid sensor input signal is shorted to ground.
The attenuation time for the rear parking aid sensors is the time required for a sensor to detect the distance to
an object expressed in milliseconds (ms).

• DTC C1701 (Left Rear Sensor Circuit Fault) - a continuous and on-demand DTC that sets when the
left rear parking aid sensor has internally failed or has an incorrect attenuation time.
• DTC C1704 (Right Rear Sensor Circuit Fault) - a continuous and on-demand DTC that sets when the
right rear parking aid sensor has internally failed or has an incorrect attenuation time.
• DTC C1707 (Rear Center Sensor Circuit Fault ) - a continuous and on-demand DTC that sets when
the left rear center parking aid sensor has internally failed or has an incorrect attenuation time.
• Dirty or obstructed parking aid sensor

• Parking aid sensor
• PAM
PINPOINT TEST D: DTCs C1701, C1704 AND C1707

D1 CHECK THE DTCs FROM THE PAM
SELF-TESTS
Yes
• Check the PAM DTCs from the continuous and DIAGNOSE the other DTCs first. REFER to
on-demand self-tests. DTC Charts in this section.
• Are parking aid DTCs other than C1701,
C1704 or C1707 recorded? No
GO to D2 .
D2 CHECK THE PARKING AID SENSOR
OPERATION
Yes
NOTE: Make sure the area around the vehicle is The system is operating correctly at this time.
clear of anything that can activate the parking The concern may have been caused by a dirty
aid system. or blocked parking aid sensor. CLEAR the
• Clean the rear bumper and sensors with
high-pressure water. No
• Carry out the azimuth system check. Refer to GO to D3 .
Azimuth System Check in this section.
• Carry out the elevation system check. Refer to
Elevation System Check in this section.
• Does the parking aid system pass both system
checks?
DISTANCE PIDs
Yes
• Make sure the suspect parking aid sensor(s) is GO to D4 .
flush-mounted in the bezel.
• Ignition ON. No
• Enter the following diagnostic mode on the scan GO to D5 .
tool: PAM DataLogger.
• With the brake pedal applied, shift the
transmission into REVERSE (R) and monitor
the parking aid sensor distance PID. The PID
PINPOINT TEST D: DTCs C1701, C1704 AND C1707 5376

will read 255 cm (8.4 ft) on a correctly

functioning sensor.
• Does the PID read 255 cm (8.4 ft)?
ATTENUATION PIDs
Yes
• Check the parking aid sensor attenuation PIDs. GO to D6 .
• Do the attenuation PIDs read between 0 and
16 ms? No
GO to D5 .
D5 CHECK THE PARKING AID SENSORS
Yes
• Install a new sensor for the suspect parking aid GO to D6 .
sensor.
• Ignition ON. No
• Clear the DTCs. Repeat the self-test. Operate the The cause of the concern was an inoperative
system and verify the concern is still present. parking aid sensor. The system is now
• Is the concern still present? operating correctly.
D6 CHECK FOR CORRECT PAM OPERATION
Yes
• Disconnect the PAM connector. INSTALL a new PAM . REFER to Parking
• Check for: Aid Module (PAM) in this section. REPEAT
♦ corrosion the self-test.
♦ damaged pins
• Connect the PAM connector and make sure it The system is operating correctly at this time.
seats correctly. The concern may have been caused by a loose
• Operate the system and determine if the concern or corroded connector.
is still present.
Pinpoint Test E: DTC B1299
Normal Operation
vehicle. A fault condition occurs when the PAM detects a short to ground or signal return circuit on the
parking aid sensor voltage circuit.
• DTC B1299 (Power Supply Sensor Circuit Short to Ground) - sets when the sensor power supply
circuit is shorted to ground or to the signal return circuit.


• PAM
PINPOINT TEST E: DTC B1299

E1 CHECK THE BUMPER WIRING HARNESS
Yes
• Inspect the bumper wiring harness for opens, GO to E2 .
shorts, grounds, or corrosion.
REPAIR or INSTALL a new bumper wiring
harness. CLEAR the DTCs. TEST the
E2 CHECK THE LH OUTER SENSOR FOR AN
INTERNAL SHORT
Yes
• Disconnect: Parking Aid Sensor C4009.
• Ignition ON. No
• Clear the DTCs. Repeat the on-demand self-test. INSTALL a new LH outer parking aid
• Is DTC B1299 still present? sensor. REFER to Parking Aid Sensor in
this section. CLEAR the DTCs. TEST the
E3 CHECK THE RH OUTER SENSOR FOR AN
INTERNAL SHORT
Yes
• Ignition ON. No
• Clear the DTCs. Repeat the on-demand self-test. INSTALL a new RH outer parking aid
• Is DTC B1299 still present? sensor. REFER to Parking Aid Sensor in
this section. CLEAR the DTCs. TEST the
E4 CHECK THE CENTER SENSOR FOR AN
INTERNAL SHORT
Yes
• Ignition ON. No
• Clear the DTCs. Repeat the on-demand self-test. INSTALL a new center parking aid sensor.
• Is DTC B1299 still present? REFER to Parking Aid Sensor in this
section. CLEAR the DTCs. TEST the
E5 CHECK PARKING AID SENSOR VOLTAGE
SUPPLY CIRCUIT FOR A SHORT TO GROUND
PINPOINT TEST E: DTC B1299 5378


• Disconnect: PAM C4014. GO to E6 .
• NOTE: The parking aid sensors should remain
disconnected in this step. No
• Measure the resistance between the PAM C4014-9, REPAIR the circuit in question. CLEAR the
circuit LMP07 (BU/WH), harness side and ground. DTCs. TEST the system for normal
operation.

E6 CHECK THE PARKING AID SENSOR
VOLTAGE SUPPLY CIRCUIT FOR A SHORT TO
THE PARKING AID SENSOR GROUND CIRCUIT
Yes
• Measure the resistance between the PAM C4014-9,
circuit LMP07 (BU/WH), harness side and the No
PAM C4014-12, circuit RMP07 (GN/WH). REPAIR the circuit in question. CLEAR the
operation.

E7 CHECK FOR CORRECT PAM OPERATION
Yes
• Disconnect the PAM connector. INSTALL a new PAM . REFER to Parking
• Check for: Aid Module (PAM) in this section. TEST
♦ corrosion the system for normal operation.
♦ damaged pins
• Connect the PAM connector and make sure it seats The system is operating correctly at this
correctly. time. The concern may have been caused by
• Operate the system and determine if the concern is a loose or corroded connector. CLEAR the
still present. DTCs. REPEAT the self-test.
Pinpoint Test F: DTC C1742 or DTC C1743
PINPOINT TEST E: DTC B1299 5379

Normal Operation
When the parking aid sensors detect obstructions in the path behind the vehicle a variable rate warning tone is
generated from a parking aid speaker. The parking aid speaker increases the warning tone rate as the vehicle
gets closer to an obstacle. A fault condition occurs when the PAM detects an open, short to ground or short to
voltage on the parking aid speaker circuits.
• DTC C1742 (Rear Sounder Circuit Failure) - sets when the sounder circuit is open or shorted to
ground.
• DTC C1743 (Rear Sounder Circuit Short to Vbat) - sets when the sounder circuit is shorted to voltage.

• PAM
• Parking aid speaker
PINPOINT TEST F: DTC C1742 OR DTC C1743

F1 CHECK THE DTCs FROM THE PAM
SELF-TESTS
Yes
• Ignition ON. Diagnose other DTCs first. REFER to
• Retrieve the PAM DTCs from the continuous and DTC Charts in this section.
on-demand self-tests.
• Are parking aid DTCs other than C1742 or No
C1743 present? GO to F2 .
F2 MEASURE THE PARKING AID SPEAKER
RESISTANCE
Yes
• Disconnect: Parking Aid Speaker C4015. If DTC C1742 was recorded, GO to F3 .
• Measure the resistance between the parking aid
speaker pin 1, component side and the parking aid If DTC C1743 was recorded, GO to F7 .
speaker pin 2, component side.
No
INSTALL a new parking aid speaker.
REFER to Parking Aid Speaker in this
section. CLEAR the DTCs. REPEAT the
self-test.
• Is the resistance between 40 and 60 ohms?

F3 CHECK THE PARKING AID SPEAKER (+)

• Connect: Parking Aid Speaker C4015. Yes

• Disconnect: PAM C4014. GO to F5 .
circuit CMP09 (BN/BU), harness side and ground. No
GO to F4 .

CIRCUIT FOR A SHORT TO GROUND WITH THE
PARKING AID SPEAKER DISCONNECTED
Yes
• Disconnect: Parking Aid Speaker C4015. REPAIR circuit RMP09 (BU/GN).
• Measure the resistance between the PAM C4014-2, CLEAR the DTCs. TEST the system for
circuit CMP09 (BN/BU), harness side and ground. normal operation.
No
REPAIR circuit CMP09 (BN/BU).
CLEAR the DTCs. TEST the system for
normal operation.

CIRCUIT FOR AN OPEN
Yes
• Disconnect: Parking Aid Speaker C4015. GO to F6 .
circuit CMP09 (BN/BU), harness side and the No
parking aid speaker C4015-2, circuit CMP09 REPAIR the circuit. CLEAR the DTCs.
(BN/BU), harness side. TEST the system for normal operation.

F6 CHECK THE PARKING AID SPEAKER (-)
CIRCUIT FOR AN OPEN
PINPOINT TEST F: DTC C1742 OR DTC C1743 5381

• Measure the resistance between the PAM C4014-6, Yes

circuit RMP09 (BU/GN), harness side and the GO to F8 .
parking aid speaker C4015-1, circuit RMP09
(BU/GN), harness side. No
REPAIR the circuit in question. CLEAR
the DTCs. TEST the system for normal
operation.

F7 CHECK THE PARKING AID SPEAKER
CIRCUITRY FOR SHORTS TO VOLTAGE
Yes
• Ignition ON. REPAIR the circuit in question. CLEAR
• Measure the voltage between the PAM C4014-2, the DTCs. TEST the system for normal
circuit CMP09 (BN/BU), harness side and ground; operation.
and between the PAM C4014-6, circuit RMP09
(BU/GN), harness side and ground. No
GO to F8 .

F8 CHECK FOR CORRECT PAM OPERATION
Yes
♦ corrosion section. CLEAR the DTCs. REPEAT the
♦ damaged pins self-test. CARRY OUT the scan tool data
♦ pushed-out pins link test.
• Connect the PAM connector and make sure it seats
correctly. No
• Operate the system and determine if the concern is The system is operating correctly at this
still present. time. The concern may have been caused
• Is the concern still present? by a loose or corroded connector. CLEAR
Pinpoint Test G: DTC U0140
Normal Operation
Several modules receive network messages from the Smart Junction Box (SJB) via the Medium Speed
Controller Area Network (MS-CAN). The following information is included in the messages:

♦ Ignition switch position
All modules receiving a particular message should exhibit a symptom if the message is missing.
• DTC U0140 (Lost Communication With Body Control Module ( GEM )) - set by the Parking Aid
Module (PAM) when network messages are missing from the SJB for greater than 5 seconds with the
ignition in RUN.
• Module communication
• PAM
• SJB
PINPOINT TEST G: DTC U0140

G1 VERIFY THE CUSTOMER CONCERN
Yes
been set due to high network
traffic or an intermittent fault
condition.
G2 CHECK THE COMMUNICATION NETWORK
Yes
Network Test. No
• Does the SJB pass the network test?
G3 RECHECK THE PAM DTCs
Yes
NOTE: If new modules were installed prior to the DTC being GO to G4 .
set, the module configuration may be incorrectly set during
Programmable Module Installation (PMI) or the PMI may not No
have been carried out. The system is operating correctly
• Clear the DTCs. Repeat the PAM self-test. been set due to high network
• Is DTC U0140 still present? traffic.
G4 CHECK FOR DTC U0140 SET IN OTHER MODULES
Yes
• Clear all DTCs. INSTALL a new SJB . REFER to
• Ignition OFF. Section 419-10 . TEST the
PINPOINT TEST G: DTC U0140 5383

Self-Test. INSTALL a new PAM . REFER

• Retrieve the continuous memory DTCs from all modules. to Parking Aid Module (PAM) in
• Is DTC U0140 set in any module? this section. TEST the system for
normal operation.
Pinpoint Test H: DTC U0155
Normal Operation
Several modules receive network messages from the Instrument Panel Cluster (IPC) via the Medium Speed
♦ Transmission gear selected

♦ Vehicle speed
♦ Parking aid disable switch status
All modules receiving a particular message should exhibit a symptom if the message is missing.
• DTC U0155 (Lost Communication With Instrument Panel Cluster ( IPC ) Control Panel) - set by the
Parking Aid Module (PAM) when network messages are missing from the IC for greater than 5
seconds with the ignition in RUN.
• Module communication
• PAM
• IPC
name="H">
PINPOINT TEST H: DTC U0155

H1 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to H2 .
been set due to high network
traffic or an intermittent fault
condition.
H2 CHECK THE COMMUNICATION NETWORK
Yes
Network Test. No
• Does the IPC pass the network test?
H3 RECHECK THE PAM DTCs

NOTE: If new modules were installed prior to the DTC being Yes
set, the module configuration may be incorrectly set during GO to H4 .
Programmable Module Installation (PMI) or the PMI may not
have been carried out. No
The system is operating correctly
• Clear the DTCs. Repeat the PAM self-test. at this time. The DTC may have
• Is DTC U0155 still present? been set due to high network
traffic.
H4 CHECK FOR DTC U0155 SET IN OTHER MODULES
Yes
• Clear all DTCs. INSTALL a new IPC . REFER to
• Ignition OFF. Section 413-01 . TEST the
Self-Test. INSTALL a new PAM . REFER
• Retrieve the continuous memory DTCs from all modules. to Parking Aid Module (PAM) in
• Is DTC U0155 set in any module? this section. TEST the system for
normal operation.
Pinpoint Test I: The Audio Volume Cutback Command Is Inoperative
Normal Operation
A variable rate warning tone is generated by the parking aid sounder. While the sounder is active, the sounder
increases its warning tone rate as the vehicle gets closer to an obstacle. When an object is detected within 46
cm (18 in) of the vehicle, the warning tone becomes continuous. A volume cutback request message is sent to
the Audio Control Module (ACM) from the Parking Aid Module (PAM) over the Medium Speed Controller
Area Network (MS-CAN) to decrease the volume of the ACM .

• PAM
• ACM
PINPOINT TEST I: THE AUDIO VOLUME CUTBACK COMMAND IS INOPERATIVE

I1 VERIFY THE PAM COMMUNICATES WITH THE
IC MESSAGE CENTER DISPLAY.
Yes
• Apply the parking brake. GO to I3 .
• Ignition ON.
• Apply the brake pedal and place the gear selector in No
REVERSE (R). GO to I2 .
• Disable/enable the parking aid system by pressing the
reset button on the message center switch.
• Can the PAM be disabled/enabled in the IPC
message center display?
PINPOINT TEST H: DTC U0155 5385

I2 CHECK THE SCAN TOOL COMMUNICATION

Yes
• NOTE: If new modules were installed prior to the DTC GO to I3 .
set during Programmable Module Installation (PMI) or No
the PMI may not have been carried out. REFER to Section 418-00 to diagnose
• Carry out the network test using the scan tool. network communication.
I3 CHECK FOR CORRECT PAM OPERATION
Yes
♦ pushed-out pins
• Connect the PAM connector and make sure it seats No
• Operate the system and determine if the concern is still time.
present.
PINPOINT TEST I: THE AUDIO VOLUME CUTBACK COMMAND IS INOPERATIVE 5386

Parking Aid - Video
Special Tool(s)

Flex Probe Kit

NOTE: The Luggage Compartment lid must be closed for correct operation of the video camera system.
The rear video camera system is used to assist the driver while reversing or parking the vehicle. For vehicles
without navigation, the image of the area behind the vehicle is displayed in the LH side of the auto-dimming
interior mirror assembly. For vehicles with navigation, the image of the area behind the vehicle is displayed in
the Front Display Interface Module (FDIM). A dashed line on the displayed image represents the center of the
vehicle and 3 color-coded lines (red, yellow, green) identify different zones between the rear of the vehicle
and objects.
NOTICE: The color-coded lines may not indicate accurate or consistent distances between objects
located be the vehicle and the rear of the vehicle. This normal condition is due to variances in vehicle
ride height, including, but not limited to, vehicle loading.
For vehicles without navigation, the signal from the rear video camera is sent to the auto-dimming interior
mirror display on a pair of shielded video circuits. For vehicles with navigation, the signal from the rear video
camera is sent to the FDIM on a pair of shielded video circuits. The displayed video image is horizontally
inverted and is viewed from the video camera perspective to mimic a conventional mirror image. The rear
video camera system is active with the ignition in RUN and the transmission selector in the REVERSE (R)
position.
For vehicles without navigation, the system remains active for approximately 3 seconds after the transmission
selector is moved from the REVERSE (R) position. The rear video camera system cannot be disabled during
these conditions.
For vehicles with navigation, the video system has a delay feature that keeps the image displayed on the
FDIM until the vehicle reaches 8km/h (5 mph) when the vehicle is shifted out of REVERSE (R). The operator
has the ability to turn the delay feature on or off with the on screen options in the FDIM . The image is not
displayed if the vehicle is shifted into PARK (P).
Parking Aid - Video 5387

2. Visually inspect for obvious signs of mechanical and electrical damage.
• Luggage Compartment lid and • Smart Junction Box (SJB) fuse(s):
video camera ♦ 41 (15A) (without navigation)
♦ 35 (10A)
• Wiring, terminals and connectors
• Video camera
• Auto-dimming interior mirror (without
navigation)
• Front Display Interface Module (FDIM) (with
navigation)
4. If the fault is not visually evident, verify the symptom. GO to Symptom Chart .
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test J: The Rear Video Is Inoperative
Normal Operation
With the ignition switch in the RUN position, voltage is supplied to the rear video camera.
For vehicles without navigation, with the gear selector in REVERSE (R) position, a reverse voltage signal is
sent to the auto-dimming interior mirror supplying power to the display in the mirror. The video camera signal
is sent to the auto-dimming interior mirror. The video signal from the video camera displays an image on the
LH side of the auto-dimming interior mirror.
For vehicles with navigation, with the gear selector in the REVERSE (R) position, a reverse signal is sent
from the IPC to the Audio Control Module (ACM) over the Medium Speed Controller Area Network
(MS-CAN), enabling the system. The video signal from the video camera displays an image on the Front
Display Interface Module (FDIM).
• Fuse
• Video camera

• Auto-dimming interior mirror (without navigation)
• FDIM (with navigation)
PINPOINT TEST J: THE REAR VIDEO IS INOPERATIVE
Section 414-01 .

J1 VERIFY VEHICLE EQUIPMENT - NAVIGATION
Yes
• Is the vehicle equipped with navigation? GO to J7 .
No
GO to J2 .
J2 CHECK THE REVERSING LAMPS OPERATION
Yes
• Check the operation of the reversing lamps. GO to J3 .
• Do the reversing lamps operate correctly?
No
J3 CHECK FOR VIDEO CAMERA SIGNAL
Yes
• Apply the parking brake.
• Ignition ON. No
• Select REVERSE. GO to J4 .
• Observe the auto-dimming interior mirror.
• Does the auto-dimming interior mirror momentarily
display a blue screen?
J4 CHECK THE AUTO-DIMMING INTERIOR MIRROR
VOLTAGE SUPPLY CIRCUIT FOR AN OPEN
Yes
• Disconnect: Auto-Dimming Interior Mirror C9039.
• Ignition ON. No
• Measure the voltage between the auto-dimming interior VERIFY the Smart Junction Box
mirror C9039-1, circuit CBP41 (BU), harness side and (SJB) fuse 41 (15A) is OK. If OK,
ground. REPAIR the circuit. If not OK,
REFER to the Wiring Diagrams
Manual to identify the possible causes
of the circuit short. TEST the system
PINPOINT TEST J: THE REAR VIDEO IS INOPERATIVE 5389


REVERSE INPUT CIRCUIT
Yes
• Apply the parking brake. GO to J6 .
• Select REVERSE.
• Measure the voltage between the auto-dimming interior No
mirror C9039-2, circuit CLS10 (GN/BN), harness side REPAIR the circuit. TEST the system
and ground. for normal operation.

GROUND CIRCUIT FOR AN OPEN
Yes
• Ignition OFF. INSTALL a new auto-dimming
• Disconnect: Negative Battery Cable. interior mirror. REFER to Section
• Measure the resistance between the auto-dimming 501-09 . TEST the system for normal
interior mirror C9039-3, circuit GD139 (BK/YE), operation.
No
REPAIR the circuit. TEST the system

J7 VERIFY THE REVERSE SIGNAL INPUT
Yes
• Apply the parking brake. GO to J8 .
• Ignition ON.
• Select REVERSE. No
• Check the IPC message center PRNDL indicator. REFER to Section 307-01A , Section
• Does REVERSE (R) appear in the message center? 307-01B or Section 307-01C to
diagnose the PRNDL.

J8 CHECK THE FDIM DISPLAY

Yes
• Select REVERSE. GO to J9 .
• Observe the FDIM display.
• Does the FDIM display "PLEASE CHECK No
SURROUNDINGS FOR SAFETY" at the top of the INSTALL a new FDIM . REFER to
display screen? Section 415-00 . TEST the system for
normal operation.
J9 CHECK THE VIDEO CAMERA VOLTAGE SUPPLY
CIRCUIT FOR AN OPEN
Yes
• Disconnect: Video Camera C4357. GO to J10 .
• Ignition ON.
• Measure the voltage between the video camera C4357-1, No
circuit CBP35 (YE/GY), harness side and ground. VERIFY that the SJB fuse 35 (10A) is
OK. If OK, REPAIR the circuit. If not
OK, REFER to the Wiring Diagrams
of the circuit short.

J10 CHECK THE VIDEO CAMERA GROUND CIRCUIT
FOR AN OPEN
Yes
• Disconnect: Negative Battery Cable.
• Measure the resistance between the video camera No
C4357-3, circuit GD171 (BK/GY), harness side and REPAIR the circuit. TEST the system
ground. for normal operation.

J11 CHECK THE VIDEO CAMERA VIDEO SIGNAL
Yes
• Measure the resistance between the video camera GO to J13 .
C4357-6, circuit VMP19 (WH/GN), harness side and
ground and the video camera C4357-7, circuit RMP19 No
(BN/VT), harness side and ground. GO to J12 .


J12 CHECK THE AUTO-DIMMING INTERIOR
MIRROR (WITHOUT NAVIGATION) OR FDIM (WITH
NAVIGATION) FOR AN INTERNAL SHORT
Yes
• Disconnect: Auto-Dimming Interior Mirror C9039 For vehicles without navigation,
(Without Navigation) or FDIM C2410 (With INSTALL a new auto-dimming
Navigation). interior mirror. REFER to Section
• Measure the resistance between the video camera 501-09 .
ground and the video camera C4357-7, circuit RMP19 For vehicles with navigation,
(BN/VT), harness side and ground. INSTALL a new FDIM . REFER to
normal operation.
No
REPAIR the circuit in question. TEST

CIRCUITS FOR A SHORT TO VIDEO SHIELD
Yes
• Measure the resistance between the video camera GO to J14 .
C4357-6, circuit VMP19 (WH/GN), harness side and the
video camera C4357-4, circuit DMP19 (BK), harness No
side. REPAIR the circuit in question. TEST
• Measure the resistance between the video camera

C4357-7, circuit RMP19 (BN/VT), harness side and the
video camera C4357-4, circuit DMP19 (BK), harness
side.


Yes
• Connect: Negative Battery Cable. REPAIR the circuit in question. TEST
• Ignition ON. the system for normal operation.
• Measure the voltage between the video camera C4357-6,
circuit VMP19 (WH/GN), harness side and ground. No
GO to J15 .
• Measure the voltage between the video camera C4357-7,

circuit RMP19 (BN/VT), harness side and ground.

J15 CHECK VIDEO SIGNAL CIRCUITS FOR AN OPEN
Yes
• Ignition OFF. REMOVE the jumper wire. CARRY
• Disconnect: Auto-Dimming Interior Mirror (Without OUT the video camera component test.
Navigation) C9039. If the camera is inoperative, INSTALL
• Disconnect: FDIM C2410 (With Navigation) . a new video camera. REFER to Video
• Connect a fused jumper wire between the video camera Camera in this section. TEST the
C4357-6, circuit VMP19 (WH/GN), harness side and the system for normal operation.
video camera C4357-7, circuit RMP19 (BN/VT),
harness side. No
REMOVE the jumper wire. GO to J16
.

• For vehicles without navigation, measure the resistance

between the auto-dimming interior mirror C9039-8,
circuit VMP19 (WH/GN), harness side and the
auto-dimming interior mirror C9039-16, circuit RMP19
(BN/VT), harness side.
• For vehicles with navigation, measure the resistance

between the FDIM C2410-3, circuit VMP19 (WH/GN),
harness side and the FDIM C2410-9, circuit RMP19

J16 CHECK VIDEO SIGNAL CIRCUIT (+) FOR AN
OPEN
Yes
• Measure the resistance between the auto-dimming REPAIR circuit RMP19 (BN/VT).
interior mirror (without navigation) or the FDIM (with TEST the system for normal operation.
navigation), harness side and the video camera, harness
side. No
REPAIR circuit VMP19 (WH/GN).
Positive
Meter Negative
Vehicle Lead Meter Lead Circuit
Fusion (without C9039-8 C4357-6 VMP19
navigation) (WH/GN)
Fusion (with C2410-3 C4357-6 VMP19
navigation) (WH/GN)

MKZ C2410-3 C4357-6 VMP19

(WH/GN)
Pinpoint Test K: Poor Image Quality
Normal Operation
For vehicles without navigation, with the gear selector in REVERSE (R) position, a reverse voltage signal is
sent to the auto-dimming interior mirror supplying power to the display in the mirror. The video camera signal
is sent to the auto-dimming interior mirror. The video signal from the video camera displays an image on the
LH side of the auto-dimming interior mirror.
For vehicles with navigation, with the gear selector in the REVERSE (R) position, a reverse signal is sent
from the IPC to the Audio Control Module (ACM) over the Medium Speed Controller Area Network
(MS-CAN), enabling the system. The video signal from the video camera displays an image on the Front
Display Interface Module (FDIM).
Poor image quality may be due to a loose ground or shield circuit in the camera wiring.

• Video camera
PINPOINT TEST K: POOR IMAGE QUALITY
Section 414-01 .

K1 CHECK THE VIDEO CAMERA GROUND CIRCUIT
FOR AN OPEN
Yes
• Disconnect: Negative Battery Cable.
• Measure the resistance between the video camera No
C4357-3, circuit GD171 (BK/GY), harness side and REPAIR the circuit. TEST the system
ground. for normal operation.


K2 CHECK THE VIDEO CAMERA VIDEO SIGNAL
Yes
• Measure the resistance between the video camera GO to K4 .
ground and the video camera C4357-7, circuit RMP19 No
(BN/VT), harness side and ground. GO to K3 .

K3 CHECK THE AUTO-DIMMING INTERIOR MIRROR
(WITHOUT NAVIGATION) OR FDIM (WITH
NAVIGATION) FOR AN INTERNAL SHORT
Yes
• Disconnect: Auto-Dimming Interior Mirror C9039 For vehicles without navigation,
(Without Navigation) or FDIM C2410 (With INSTALL a new auto-dimming
Navigation). interior mirror. REFER to Section
• Measure the resistance between the video camera 501-09 .
ground and the video camera C4357-7, circuit RMP19 For vehicles with navigation,
(BN/VT), harness side and ground. INSTALL a new FDIM . REFER to
normal operation.
No

K4 CHECK THE VIDEO CAMERA VIDEO SIGNAL
CIRCUITS FOR A SHORT TO VIDEO SHIELD
PINPOINT TEST K: POOR IMAGE QUALITY 5396

• Measure the resistance between the video camera Yes

C4357-6, circuit VMP19 (WH/GN), harness side and the GO to K5 .
side. No
• Measure the resistance between the video camera

C4357-7, circuit RMP19 (BN/VT), harness side and the
side.

K5 CHECK VIDEO SIGNAL CIRCUITS FOR AN OPEN
Yes
• Ignition OFF. REMOVE the jumper wire. CARRY
• Disconnect: Auto-Dimming Interior Mirror (Without OUT the video camera component
Navigation) C9039. test. If the camera is inoperative,
• Disconnect: FDIM C2410 (With Navigation) . INSTALL a new video camera.
• Connect a fused jumper wire between the video camera REFER to Video Camera in this
C4357-6, circuit VMP19 (WH/GN), harness side and the section. TEST the system for normal
video camera C4357-7, circuit RMP19 (BN/VT), harness operation.
side.
No
REMOVE the jumper wire. GO to K6
.
• For vehicles without navigation, measure the resistance

between the auto-dimming interior mirror C9039-8,
circuit VMP19 (WH/GN), harness side and the
auto-dimming interior mirror C9039-16, circuit RMP19

• For vehicles with navigation, measure the resistance

between the FDIM C2410-3, circuit VMP19 (WH/GN),
harness side and the FDIM C2410-9, circuit RMP19

K6 CHECK VIDEO SIGNAL CIRCUIT (+) FOR AN OPEN
Yes
• Measure the resistance between the auto-dimming REPAIR circuit RMP19 (BN/VT).
interior mirror (without navigation) or the FDIM (with TEST the system for normal
navigation), harness side and the video camera, harness operation.
side.
No
REPAIR circuit VMP19 (WH/GN).
operation.
Positive
Meter Negative
Vehicle Lead Meter Lead Circuit
Fusion (without C9039-8 C4357-6 VMP19
navigation) (WH/GN)
Fusion (with C2410-3 C4357-6 VMP19
navigation) (WH/GN)
MKZ C2410-3 C4357-6 VMP19
(WH/GN)

Pinpoint Test L: The Rear Video Mirror Display Is Always On (Vehicles Without Navigation)
Normal Operation
The video camera receives a supply voltage, with the ignition switch in the RUN position. When the gear
selector is in the REVERSE (R) position, a reverse voltage signal is sent to the auto-dimming interior mirror
supplying power to the display in the mirror. The video camera signal is sent to the auto-dimming interior
mirror. The video signal from the video camera displays an image on the LH side of the auto-dimming interior
mirror.

• Auto-dimming interior mirror
PINPOINT TEST L: THE REAR VIDEO MIRROR DISPLAY ALWAYS ON (VEHICLES WITHOUT NAVIGATION)

L1 CHECK THE REVERSING LAMPS
OPERATION
Yes
• Check the operation of the reversing lamps GO to X2 .
• Do the reversing lamps operate correctly?
No
L2 CHECK FOR CORRECT AUTO-DIMMING
INTERIOR MIRROR OPERATION
Yes
• Disconnect the auto-dimming interior mirror INSTALL a new auto-dimming interior mirror.
connector. REFER to Section 501-09 . TEST the system
• Check for: for normal operation.
♦ corrosion
♦ damaged pins No
♦ pushed-out pins The system is operating correctly at this time.
• Connect the auto-dimming interior mirror The concern may have been caused by a loose
connector and make sure it seats correctly. or corroded connector.
• Operate the system and determine if the concern
is still present.
Component Test - Video Camera
Fusion/MKZ

Measure the resistance between the video camera pins, component side, as follows:
Video Camera Pins Resistance

3 and 6 38-49 ohms 3 and 7 39-48 ohms
6 and 7 74-101 ohms
4 and 6 38-49 ohms
If the resistance values for the video camera are within the specifications listed, the video camera is functional
at this time.
If the resistance values for the video camera are not within the specifications listed, the video camera is
inoperative at this time. Install a new video camera. Refer to Video Camera in this section. Test the system for
normal operation.
PINPOINT TEST L: THE REAR VIDEO MIRROR DISPLAY ALWAYS ON (VEHICLES WITHOUT
5400
NAVIGAT
Azimuth System Check
Minimum Detectable Object Locations
NOTE: The object used in this system check can be fabricated from 9 cm O.D. (3 in I.D) plastic pipe 100 cm
(39 in) in length (available as Polyvinyl Chloride (PVC) pipe, or similar from a hardware or plumbing
supply).
NOTE: The following Parking Aid Module (PAM) system check should be carried out with the vehicle on a
level surface. The specified object locations are approximate, not absolute.
NOTE: The parking aid system will default to on when the ignition key is cycled from off to on.
NOTE: The scan tool may be used to monitor distance PIDs. The distance PIDs read between 0 and 255 cm
(0 and 8 ft) on a correctly functioning system.
1. Turn the ignition to the ON position, engine off.
2. Set the parking brake on.
3. Place the gear shift in REVERSE (R).
4. Verify that the parking aid system detects the specified object when placed within the 3 specified
locations (P1, P2, P3). The pipe should be inside of these locations.
• The speaker should beep slowly when objects are detected on the outer edges of the detection
zone, and increase as the object is moved closer to the vehicle.
When the object is within 25 cm (10 in) of the rear bumper, the sounder should be on
continuously.
• If the Parking Aid Module (PAM) does not detect the object above, refer to Parking Aid in
the Diagnosis and Testing portion of this section.
Azimuth System Check 5401

Minimum Detectable Object Locations 5402

Elevation System Check
1. NOTE: The following system check should be carried out with the vehicle on a 3.0 m wide by 4.5 m
deep (10 ft wide by 15 ft deep) smooth concrete surface, free of all obstacles and noise from fan and
pneumatic tools.
Turn the ignition to the ON position, engine off.
2. Set the parking brake.
3. Place the gear shift in REVERSE (R).
4. Verify that no audible alerts are heard. If audible alerts are heard, check to make sure the bumper is
correctly installed and is not tilted downward so that the sensor is pointing at the ground.
• If the audible warning tone is heard, refer to Parking Aid in the Diagnosis and Testing portion
of this section.
Elevation System Check 5403


Manual
REMOVAL AND
INSTALLATION
Parking Aid Module (PAM)

1 15K866 Parking Aid Module (PAM)
2 W706350 PAM screws (2 required)
3 - PAM electrical connectors (part of 13A412)
1. NOTE: Module configuration is only required if a new Parking Aid Module (PAM) is being installed.
Upload the PAM configuration information to the scan tool. For additional information, refer to PMI
in Section 418-01 .
2. Remove the LH rear seat bolster. For additional information, refer to Section 501-10 .
3. Remove the 2 screws and the PAM .


• Download the PAM configuration information. For additional information, refer to Section
418-01 .
Parking Aid Module (PAM) 5404

Parking Aid Module (PAM) 5405


Manual
REMOVAL AND
INSTALLATION
Parking Aid Speaker

1 W713167 Parking aid speaker push pins (2 required)
2 15K864 Parking aid speaker
3 - Parking aid speaker electrical connector (part of
13A412)
1. Remove the parcel shelf. For additional information, refer to Section 501-05 .
2. Remove the 2 push pins and the parking aid speaker.

Parking Aid Speaker 5406

Parking Aid Speaker 5407


Manual
REMOVAL AND
INSTALLATION
Parking Aid Sensor

1 15K859 Parking aid sensor(s)
2 - Parking aid sensor electrical connectors (part of
14N139)
1. Remove the rear bumper cover. For additional information, refer to Section 501-19 .
2. Disconnect the parking aid sensor(s) electrical connector(s).
3. Pry the retaining tabs with a suitable tool, such as a flat bladed screwdriver and remove the parking
aid sensor(s).

• Carry out the azimuth and elevation system check. For additional information, refer to
Azimuth System Check and Elevation System Check in this section.
Parking Aid Sensor 5408

Parking Aid Sensor 5409


Manual
REMOVAL AND
INSTALLATION
Video Camera
Fusion

1 W506842 Video camera screws (2 required)
2 19G490 Video camera
3 - Luggage compartment lid applique
MKZ

1 19G490 Video camera
2 - Video camera electrical connector (part of 13A412)
All vehicles
Video Camera 5410

1. Remove the liftgate trim panel. For additional information, refer to Section 501-08 .
• Position the water shield aside.
Fusion
2. Remove the luggage compartment lid panel applique. For additional information, refer to Section
501-08 .
3. Remove the 2 screws and the video camera and bracket assembly.
MK
4. Remove the video camera by prying on the two outer retaining tabs with a suitable tool, such as a flat
bladed screwdriver.
All vehicles
MKZ 5411

SECTION 414-00: Charging System
Manual
Material
Item Specification
Fill
Capacity
XO-5W20-QSP (US);
Premium Motor Oil
equivalent
Item Specification
Generator - 2.5L
Generator pulley ratio 2.45:1
Rating 90 amps @ 700 rpm (min) to 150 amps @ 2,500 rpm (max)
Voltage regulator type Electronic internal with generator
Generator - 3.0L
Generator - 3.5L

Generator B+ terminal nut 12 - 106
Generator bolts 47 35 -
Generator stud nuts 47 35 -
Generator stud (2.5L) 24 18 -
Generator stud (3.5L) 8 - 71
Generator upper air duct screws (2.5L) 4 - 35
Radial arm adapter nut 9 - 80
MKZ 5412
RH wheel splash shield screws 8 - 71
MKZ 5413

Manual
Charging System
The charging system is a negative ground system consisting of:
• a generator with an internal voltage regulator.

• a charging system warning indicator.
• a battery.
• circuitry and cables.
• a PCM.
• a radial arm adapter (if equipped, serviceable separately from the generator)
The generator is driven by the accessory drive belt. When the engine is started, the generator begins to
generate AC which is internally converted to DC. The DC is controlled by the voltage regulator (located on
the rear of the generator) and supplied to the battery. The PCM controls the voltage regulation set point,
working with the generator internal voltage regulator over 2 control and communication circuits.
Charging System 5414


Manual
The PCM-controlled charging system, or "Smart Charge" charging system, determines the optimal voltage set
point for the charging system and communicates this information to the voltage regulator. The "Smart
Charge" charging system is designed to set 1 of 6 DTCs any time a charging system fault is present. All of the
DTCs can set continuous faults, but not all DTCs will set as on-demand faults.
DTC KOEO KOER Continuous

P0562 X X X
P0563 X a Xa
P0620 X
P0625 X X
P0626 X X
P065B X
a Requires vehicle speed above 8 mph.
This system uses 2 communication lines between the PCM and the generator/voltage regulator. Both of these
communication lines use Pulse-Width Modulation (PWM). The generator communication (GENCOM) line
communicates the desired set point from the PCM to the voltage regulator. The generator monitor
(GENMON) line communicates the generator load and error conditions to the PCM. The GENCOM
command is only sent by the PCM when it is necessary to adjust the voltage set point. If the set point does not
need to be changed, several seconds may elapse between PCM GENCOM commands. This normal operation
will appear in the PID as occasional "bursts" of pulse-width commands. The third pin on the voltage regulator,
the A circuit pin, is a circuit dedicated to monitor or sense battery voltage.
The PCM simultaneously controls and monitors the output of the generator. When the current consumption is
high or the battery is discharged, the PCM will raise engine speed as needed to increase generator output. The
generator charges the battery and at the same time supplies power for all of the electrical loads that are
required. The battery is more effectively charged with a higher voltage when the battery is cold and a lower
voltage when the battery is warm. The PCM is able to adjust the charging voltage according to the battery
temperature by using a signal from the Intake Air Temperature (IAT) sensor. The PCM also uses other inputs
to control charging system voltage such as the Vehicle Speed Sensor (VSS) and Engine Coolant Temperature
(ECT). The voltage set point is calculated by the PCM and communicated to the voltage regulator by the
GENCOM circuit based on the needs of the vehicle and the conditions.
The PCM turns off the generator during cranking to reduce the generator load and improve cranking speed.
Once the engine starts, the PCM slowly increases generator output to desired voltage.
The PCM controls the charging system warning indicator by sending a message over the High Speed
Controller Area Network (HS-CAN) to the Instrument Cluster (IC) or Instrument Panel Cluster (IPC). The IC
/ IPC will then control charging system warning indication based on the message from the PCM. The status of
the PCM charging system warning indicator and/or message can be confirmed by viewing PCM PID
generator fault indicator lamp (GENFIL). Any charging system fault detected by the PCM will result in 1 or
more DTCs being set and the PID GENFIL having a status of On. If equipped with a charging system warning
indicator, the IC / IPC will turn the indicator ON or OFF. If equipped with a message center, the IC / IPC will
Principles of Operation 5415

display a CHECK CHARGING SYSTEM message. When the ignition is ON and the engine is OFF on
vehicles equipped with a message center, the CHECK CHARGING SYSTEM message may not be displayed.
For information regarding the IC / IPC and message center, refer to Section 413-01 .
Under certain circumstances, the charging system may have a concern, but will still keep the battery charged
and the vehicle running. GENCOM is normally used to initiate charging, but the generator may charge with a
fault in this circuit. If the engine is operated at greater than 2,000 rpm momentarily, the generator may
"self-excite" or start charging on its own. The charging system warning indicator is illuminated and/or
CHECK CHARGING SYSTEM message is displayed, and the generator operates in a default mode
(approximately 13.5 volts) until the engine is turned off. When the engine is restarted and the engine is
operated at greater than 2,000 rpm momentarily, the generator may again self-excite and again the charging
system warning indicator is illuminated and/or CHECK CHARGING SYSTEM message is displayed.
The PIDs and their associated descriptions used in the charging system diagnosis are listed below:
PID Chart
Associated Circuit Connector,

PID Description Normal Display Name Circuit
GENMON Generator Constant fluctuating percentage Generator monitor C102A-1,
Monitor 3%-98% (GENMON) CDC15 (VT)
GENCMD Generator Fluctuating percentage or small Generator C102A-2,
Command intermittent bursts 3%-98% communication CDC10
(GENCOM) (BU/OG)
GENVDSD Generator Voltage Voltage varies by vehicle needs - -
Desired - May be controlled by an
output state control
GENFIL Generator Fault OFF if charging system is OK - -
Indicator Lamp
GENCMD_LF Generator NO FAULT if GENCOM - -
Command Line circuit (GENCMD PID) is OK
Fault
GENMON_HZ Generator Frequency value - -
Monitor
Frequency
VPWR Module Supply Within 0.5 volt of battery - -
Voltage voltage
RPM Engine Engine rpm - May be controlled - -
Revolutions Per by an output state control
Minute



Manual
Inspection And Verification
Special Tool(s)

WARNING: Batteries contain sulfuric acid and produce explosive gases. Work in a well-ventilated
area. Do not allow the battery to come in contact with flames, sparks or burning substances. Avoid
contact with skin, eyes or clothing. Shield eyes when working near the battery to protect against
possible splashing of acid solution. In case of acid contact with skin or eyes, flush immediately with
water for a minimum of 15 minutes, then get prompt medical attention. If acid is swallowed, call a
physician immediately. Failure to follow these instructions may result in serious personal injury.
WARNING: Always lift a plastic-cased battery with a battery carrier or with hands on opposite
corners. Excessive pressure on the battery end walls may cause acid to flow through the vent caps,
resulting in personal injury and/or damage to the vehicle or battery.
NOTICE: Do not make jumper connections except as directed. Incorrect connections may damage the
voltage regulator test terminals or fuses.
NOTICE: Do not allow any metal object to come in contact with the generator housing and internal
diode cooling fins. A short circuit may result and burn out the diodes.
NOTE: While carrying out any pinpoint test, disregard any DTCs set while following a specific pinpoint test.
After the completion of a test, be sure to clear all DTCs in the PCM.
NOTE: All voltage measurements are referenced to the negative (-) battery post unless otherwise specified.
• Battery • Wiring, terminals or

• Front End Accessory Drive connectors
(FEAD) belt • Cables
• Generator pulley • Battery
• Generator
• Fuses
Inspection And Verification 5418

4. Verify the battery condition. Refer to Section 414-01 .


• verify the ignition is ON.
♦ The air bag warning indicator prove-out (other indicators may NOT prove ignition is
on) confirms ignition on. If ignition does not turn on, refer to Section 211-05 to
diagnose no power in RUN.
• refer to Section 418-00 , Inspection and Verification, to establish a scan tool session (without
the ignition on).

418-00 .
NOTE: Use the Integrated Diagnostic System (IDS) feature that retrieves all Continuous Memory Diagnostic
Trouble Codes (CMDTCs) from all modules at one time.
9. Retrieve CMDTCs from all modules.
10. NOTE: If no charging system DTCs are present, the charging system is operating correctly. If the
charging system has a concern, it usually sets a charging system DTC.
If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Chart in
this section. For all other DTCs, refer to the Master DTC Chart in Section 419-10 or Powertrain
Control/Emissions Diagnosis (PC/ED) manual.
11. If no DTCs related to the concern are retrieved, go to the Symptom Chart in this section.



Manual
Diagnostic Trouble Code (DTC) Chart
DTCs Description Source Action

P0563 System Voltage High PCM GO to Pinpoint Test A .
P0563 System Voltage High Various GO to Pinpoint Test A
Modules
P0620 Generator Control Circuit PCM GO to Pinpoint Test C .
P0625 Generator Field Terminal PCM GO to Pinpoint Test D .
Circuit Low
P0626 Generator Field Terminal PCM GO to Pinpoint Test D .
Circuit High
P065B Generator Control Circuit PCM GO to Pinpoint Test E .
Range/Performance
All other - Various REFER to the Master DTC Chart in Section 419-10 or the
DTCs Modules Powertrain Control/Emissions Diagnosis (PC/ED) manual.
If directed to this section from another section, GO to
Symptom Chart in this section.
Diagnostic Trouble Code (DTC) Chart 5421


Manual
Symptom Chart
Symptom Chart
Symptom Chart 5422


Manual
Pinpoint Test
Special Tool(s)
Backprobe Pins
POM 6411
Flex Probe Kit

300-NUD105-R025DE or equivalent

Test Light SGT27000 or equivalent 250-350

mA incandescent bulb test lamp
SGT27000
Pinpoint Test A: System Voltage High
Refer to Wiring Diagrams Cell 12 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Charging System for
NOTE: DTC P0563, B1317 or B1676 can be set if the vehicle has been recently jump started, the battery has
been recently charged or the battery has been discharged. The battery may become discharged due to
excessive load(s) on the charging system from aftermarket accessories or if vehicle accessories have been
operating for an extended period of time without the engine running.
Normal Operation
With the engine running, the charging system supplies voltage to the battery and the vehicle electrical system
through the battery B+ cable. The voltage that is supplied to the vehicle electrical system is used for the
operation of the various vehicle systems and modules. Many modules monitor this voltage and if it rises
above their calibrated set point, a DTC will be set.
• DTC P0563 (System Voltage High) - If the PCM detects a voltage from the charging system higher
than 15.2 volts with vehicle speed above 8 km/h (5 mph), this DTC will be set.

• Fuse
• Engine, generator and battery grounds
• Battery
Pinpoint Test 5423

• Generator
• PCM
PINPOINT TEST A: SYSTEM VOLTAGE HIGH
NOTE: Make sure battery voltage is greater than 12.2 volts prior to and during this pinpoint test.
NOTE: Do not have a battery charger attached during vehicle testing.

A1 CHECK BATTERY CONDITION
Yes
• Refer to Section 414-01 and carry out Pinpoint GO to A2 .
Test A: Battery Condition Test to determine if the
battery can hold a charge and is OK for use. No
• Does the battery pass the condition test? INSTALL a new battery. REFER to Section
414-01 . CLEAR the DTCs. REPEAT the
operation.
A2 CHECK FOR DTCs IN THE PCM
Yes
• Enter the following diagnostic mode on the scan REFER to the DTC Chart in this section for
tool: Self Test - PCM. the correct pinpoint test and DIAGNOSE
• Is DTC P0620, P0625, P0626 or P065B present? those DTCs first.
No
GO to A3 .
A3 MONITOR PCM PID GENERATOR VOLTAGE
DESIRED (GENVDSD)
Yes
• Start the engine. GO to A4 .
• NOTE: Many of the PCM PIDs selected will be
monitored later in this pinpoint test. No
• Select and monitor the following PCM PIDs: GO to A11 .
♦ Generator Monitor (GENMON)
♦ Generator Command (GENCMD)
♦ Generator Voltage Desired (GENVDSD)
♦ Module Supply Voltage (VPWR)
• Monitor the GENVDSD PID.
• Does the GENVDSD PID indicate 15.1 volts or
less?
A4 MONITOR PCM PID GENERATOR VOLTAGE
DESIRED (GENVDSD)
Yes
• With the engine still running at idle, measure The fault is not present at this time. This
battery voltage and record. may indicate an intermittent fault. CARRY
OUT a wiggle test on the charging system
circuits to try and RECREATE the concern.
CHECK generator connections for
corrosion, loose connections and/or bent

terminals. REPAIR as necessary. CLEAR

No
GO to A5 .
• Monitor the GENVDSD PID.
• Is battery voltage within ±0.6 volt of the PID
GENVDSD?
A5 MEASURE THE SENSE VOLTAGE
Yes
• Disconnect: Generator C102A.
• Ignition ON. No
• Measure battery voltage and record. VERIFY Battery Junction Box (BJB) fuse
17 (10A) is OK. If OK, REPAIR circuit
SBB17 (RD). If not OK, REFER to the
Wiring Diagrams manual to identify the
• Measure the voltage between generator C102A-3,

circuit SBB17 (RD), harness side and ground.
• Is the A sense voltage equal to battery voltage?

A6 A SENSE CIRCUIT LOAD TEST
Yes
NOTICE: The following step uses a test light to GO to A7 .
simulate normal circuit loads. Use only the test
light recommended in the Special Tools table at No
the beginning of this section. To avoid REPAIR resistance due to corroded or loose
connector terminal damage, use the Flex Probe connection on circuit SBB17 (RD).
Kit for the test light probe connection to the INSPECT generator C102A-3, circuit
vehicle. Do not use the test light probe directly SBB17 (RD) for damage. CLEAR the
on any connector. DTCs. REPEAT the self-test. TEST the
NOTE: This step puts a load on the A sense
circuit. If there are corroded or loose connections,
loading the circuit may help show the fault. A
250-350 mA incandescent 12-volt test lamp is
required for this step. This circuit will not be
PINPOINT TEST A: SYSTEM VOLTAGE HIGH 5425

loaded properly using an LED-style test lamp.
• Using a 12-volt test lamp connected to ground,

check for voltage at generator C102A-3, circuit
SBB17 (RD), harness side.

A7 CHECK THE GENERATOR OUTPUT
Yes
• Start the engine. INSTALL a new generator. REFER to
• Increase engine rpm until generator starts to Generator - 2.5L , Generator - 3.0L or
generate output. Generator - 3.5L in this section. CLEAR the
• With the engine running, measure battery voltage DTCs. REPEAT the self-test. TEST the
and record. system for normal operation.
No
GO to A8 .
• Is the voltage above 14.5 volts?

A8 MONITOR PCM PIDs GENERATOR
COMMAND (GENCMD), GENERATOR MONITOR
(GENMON) AND GENERATOR VOLTAGE
DESGENVDSD)
Yes
• Connect a fused jumper wire between generator
C102A-1, CDC15 (VT), harness side and No
generator C102A-2, circuit CDC10 (BU/OG), INSTALL a new PCM. REFER to Section
harness side. 303-14A for 2.5L engines, Section 303-14B
for 3.0L engines or Section 303-14C for
3.5L engines. CLEAR the DTCs. REPEAT
the self-test. TEST the system for normal
operation.

• Monitor the GENVDSD, GENMON and

GENCMD PIDs.
• Using the active command, set GENVDSD PID to
14 volts.
• Does the GENCMD PID read within 5% of
GENMON PID?
A9 COMPARE PCM SUPPLY VOLTAGE (VPWR)
PID TO BATTERY VOLTAGE
Yes
• With the engine still running at idle, measure the INSTALL a new generator. REFER to
battery voltage at the battery and monitor the PCM Generator - 2.5L , Generator - 3.0L or
VPWR PID. Generator - 3.5L in this section. CLEAR the
No
GO to A10 .
• Does PCM VPWR PID accurately display

battery voltage within ±0.5 volt?
A10 CHECK PCM SUPPLY VOLTAGE CIRCUITS
Yes
• Disconnect: Fused Jumper Wire.
• Disconnect: PCM C175B (2.5L and 3.0L). No
• Disconnect: PCM C175E (3.5L). REPAIR high resistance or loose
• For 2.5L and 3.0L vehicles, inspect the connector connections in the affected circuit(s).
pins for damage. Measure resistance between BJB CLEAR the DTCs. REPEAT the self-test.
fuse 47 (15A), output side and: TEST the system for normal operation.
♦ PCM C175B-51, circuit CBB47 (GN/BU),
harness side.
harness side.
harness side.

• For 3.5L engines, measure the resistance between

BJB Fuse 47 (15A) output side and:
♦ PCM C175E-67, circuit CBB46 (WH/BU)
hness side.
♦ PCM C175E-68, circuit CBB46 (WH/BU)
harness side.
• Are the resistances less than 0.5 ohm?

A11 CHECK FOR CORRECT PCM OPERATION
Yes
• Check the PCM harness and component side 303-14A for 2.5L engines, Section 303-14B
connectors for: for 3.0L engines or Section 303-14C for
♦ corrosion. 3.5L engines. CLEAR the DTCs. REPEAT
♦ pushed-out/bent pins. the self-test. TEST the system for normal
• Connect the PCM and generator, make sure the operation.
connectors seat correctly.
• Operate the system and determine if the concern is No
still present. The system is operating correctly at this
• Is the concern still present? time. The concern may have been caused by
a loose or corroded connector. CLEAR the

Pinpoint Test B: System Voltage Low or Battery is Discharged
Normal Operation
With the engine running, the charging system supplies voltage to the battery and the vehicle electrical system
through the battery B+ cable. The PCM monitors this voltage through the battery positive post through the
Battery Junction Box (BJB). If this voltage drops 1.5 volts or more below the generator voltage desired, this
DTC will be set after 30 seconds.
• DTC P0562 (System Voltage Low) - If the PCM detects a voltage from the charging system that is
1.5 volts lower than the generator voltage desired, this DTC will be set.

• Fusible link
• Radial arm adapter
• Battery
• Generator
• PCM
PINPOINT TEST B: SYSTEM VOLTAGE LOW OR BATTERY IS DISCHARGED

B1 CHECK FOR OTHER PCM DTCs
Yes
• Enter the following diagnostic mode REFER to the DTC Chart in this section for the correct
on the scan tool: Self Test - PCM. pinpoint test and DIAGNOSE those DTCs first.
• Is DTC P0620, P0625, P0626 or
P065B present? No
GO to B2 .
B2 CHECK BATTERY CONDITION
Yes
• Refer to Section 414-01 and carry out GO to B3 .
Pinpoint Test A: Battery Condition
Test to determine if the battery can No
hold a charge and is OK for use. INSTALL a new battery. REFER to Section 414-01 .
• Does the battery pass the condition TEST the system for normal operation.
test?
B3 CHECK THE GENERATOR
CONNECTIONS


• Inspect generator C102A connection. GO to B4 .
Connector should be installed
correctly and tight. No
• Disconnect: Generator C102A. TIGHTEN or INSTALL a new C102B (B+ nut) and/or
• Inspect generator C102A for bent radial arm adapter as needed. REFER to Specifications in
and/or pushed-out pins. this section. VERIFY the fusible link is OK. If the fusible
• Inspect generator C102B, B+ circuit link is OK, REPAIR circuit SDC14 (RD). If not OK,
SDC14 (RD) and radial arm adapter REFER to the Wiring Diagrams manual to identify the
connection(s). Connection should be possible causes of the circuit short. CLEAR the DTCs.
tight. REPEAT the self-test. TEST the system for normal
• Measure the battery voltage. operation.
• Measure the voltage between

generator C102B, B+ circuit SDC14
(RD) and ground.
• Are the generator C102B and radial

arm adapter connections tight and
does the generator B+ measure
battery voltage?
B4 CHECK THE VOLTAGE DROP IN
THE B+ CIRCUIT
Yes
• Connect: Generator C102A. GO to B5 .
• With the engine running at idle, No
headlamps on and blower on high, INSPECT circuit SDC14 (RD), radial arm adapter and
measure the voltage drop between the positive battery cable for loose connections, physical
generator B+ C102B, circuit SDC14 damage or wire corrosion. REPAIR as required. CLEAR
(RD) and the positive battery the DTCs. REPEAT the self-test. TEST the system for
terminal. normal operation.
PINPOINT TEST B: SYSTEM VOLTAGE LOW OR BATTERY IS DISCHARGED 5430

• Carry out a wiggle test of the

generator wiring and connections
while measuring voltage drop.
• Is the voltage drop less than 0.5
volt?
B5 COMPARE PCM MODULE SUPPLY
VOLTAGE (VPWR) PID
Yes
• With the engine still running at idle, GO to B6 .
headlamps on and blower on high,
measure the battery voltage at the No
battery and monitor the PCM VPWR REPAIR high resistance or loose connections in the
PID. affected PCM power circuit(s). CLEAR the DTCs.
operation.
• Does PCM VPWR PID display

battery voltage within ±0.5 volt?
B6 CHECK PCM GROUND FOR HIGH
RESISTANCE
Yes b>
• Monitor PCM VPWR PID. GO to B7 .
• With the engine still running at idle,
turn off all accessory loads, measure No
the battery voltage at the battery and REPAIR the affected PCM ground circuits. CLEAR
note the PCM VPWR PID. the DTCs. REPEAT the self-test. TEST the system for
normal operation.
• With the engine still running at idle,

turn headlamps on and blower on
high, measure the battery voltage at
the battery and monitor the PCM
VPWR PID.

• Does the VPWR PID read within

±0.5 volt with accessory loads on as
compared to accessory loads off?
B7 MONITOR PID VPWR AT WOT
Yes
• With the engine still running at idle, GO to B8 .
turn off all accessory loads, measure
the battery voltage at the battery and No
monitor the PCM VPWR PID. INSTALL a new PCM. REFER to Section 303-14A for
2.5L, Section 303-14B for 3.0L and Section 303-14C for
3.5L engines.
• Monitor the VPWR PID and

momentarily accelerate the engine to
Wide Open Throttle (WOT) and
release. Repeat this step 4-5 times
while continuing to monitor the
VPWR PID.
• Does the VPWR PID stay within 0.5
volt of battery voltage when the
engine rpms are increased?
B8 CHECK FOR DISCHARGED
BATTERY
Yes
• With the engine still running at idle, CARRY OUT the Component Test, Battery - Drain Test.
measure the battery voltage at the REFER to Section 414-01 .
battery.
• Monitor PCM PIDs generator voltage No
desired (GENVDSD) and generator VERIFY BJB fuse 17 (10A) is OK. If OK, REPAIR
monitor (GENMON). circuit SBB17 (RD). If not OK, REFER to the Wiring
• Does GENMON PID frequently rise Diagrams manual to identify the possible causes of the
above 90% and battery voltage circuit short. CLEAR the DTCs. REPEAT the self-test.
drop below GENVDSD PID by 0.5 TEST the system for normal operation.
volt or more?
Pinpoint Test C: DTC P0620

Normal Operation
The PCM monitors the generator output via the GENMON circuit. The PCM uses the GENCOM circuit to
command the generator to either increase or decrease output. If the GENCOM circuit (generator control
circuit) or the A sense circuit are open or shorted to ground, the PCM will be unable to control the generator
output. When the engine speed rises above approximately 2,000 rpm, the generator will default to a steady
voltage output of approximately 13.5 volts and the PCM will send a request to the Instrument Cluster (IC) to
illuminate the charging system warning indicator. A GENCOM circuit fault can be confirmed by viewing the
PCM PID generator command line fault (GENCMD_LF) (YES status indicator fault).
• DTC P0620 (Generator Control Circuit) - If the GENCOM circuit or A sense circuit are open or
shorted to ground, the PCM will set this DTC.

• Fuse
• Generator
• PCM
PINPOINT TEST C: DTC P0620

C1 CHECK THE BATTERY CONDITION
Yes
• Refer to Section 414-01 and carry out Pinpoint GO to C2 . br>
Test A: Battery Condition Test to determine if No
the battery can hold a charge and is OK for use. INSTALL a new battery. REFER to Section
• Does the battery pass the condition test? 414-01 . CLEAR the DTCs. REPEAT the
operation.
C2 CHECK THE GENERATOR CONNECTIONS
Yes
• Inspect generator C102A connection. Connector
should be installed correctly and tight. No
• Disconnect: Generator C102A. TIGHTEN or INSTALL a new C102B (B+
• Inspect generator C102A for bent and/or nut) and/or radial arm adapter as needed.
pushed-out pins. REFER to Specifications in this section.
• Inspect generator C102B, B+ circuit SDC14 VERIFY the fusible link is OK. If the fusible
(RD) and radial arm connection(s). Connection link is OK, REPAIR circuit SDC14 (RD). If
should be tight. not OK, REFER to the Wiring Diagrams
• Measure the battery voltage. manual to identify the possible causes of the
circuit short. CLEAR the DTCs. REPEAT the

operation.
• Measure the voltage between generator C102B,

B+ circuit SDC14 (RD) and ground.
• Are the generator C102B and radial arm

adapter connections tight and does the
generator B+ measure battery voltage?
C3 CHECK THE VOLTAGE DROP IN THE B+
CIRCUIT
Yes
• Connect: Generator C102A. GO to C4 .
• With the engine running at idle, headlamps on No
and blower on high, measure the voltage drop INSPECT circuit SDC14 (RD), radial arm
between generator B+ C102B, circuit SDC14 adapter and the positive battery cable for loose
(RD) and the positive battery terminal. connections, physical damage or wire
corrosion. REPAIR as necessary. CLEAR the
• Carry out a wiggle test of the generator wiring

and connections while measuring voltage drop.
• Is the voltage drop less than 0.5 volt?
C4 A SENSE CIRCUIT LOAD TEST
Yes
NOTICE: The following step uses a test light GO to C5 .
to simulate normal circuit loads. Use only the
test light recommended in the Special Tools No
table at the beginning of this section. To avoid VERIFY Battery Junction Box (BJB) fuse 17
connector terminal damage, use the Flex (10A) is OK. If OK, REPAIR circuit SBB17
Probe Kit for the test light probe connection (RD). If not OK, REFER to the Wiring
to the vehicle. Do not use the test light probe Diagrams manual to identify the possible
PINPOINT TEST C: DTC P0620 5434

directly on any connector. causes of the circuit short. CLEAR the DTCs.
NOTE: This step puts a load on the A sense normal operation.
circuit. If there are corroded or loose
connections, loading the circuit may help show
the fault. A 250-350 mA incandescent 12-volt
test lamp is required for this step. This circuit
will not be loaded properly using an LED-style
test lamp.
• Ignition OFF.
• Ignition ON.
check for voltage at generator C102A-3, circuit
SBB17 (RD), harness side.

C5 CHECK THE GENERATOR COMMAND
LINE FAULT (GENCMD_LF) PID
Yes
• Connect: Generator C102A.
• NOTE: Many of the PCM PIDs selected will be GO to C9 .
monitored later in this pinpoint test.
• Select and monitor the following PCM PIDs:
♦ Generator Monitor (GENMON)
♦ Generator Command (GENCMD)
♦ Generator Command Line Fault
(GENCMD_LF)
• With the engine running at idle, monitor the
GENCMD_LF PID.
• Does the GENMON_LF PID indicate
FAULT?
CIRCUIT FOR A SHORT TO POWER
Yes
• Ignition ON. No
• Measure the voltage between generator GO to C11 .
C102A-2, circuit CDC10 (BU/OG), harness side
and ground.

• Does voltage read 1 volt or less?

C7 COMPARE THE PCM PIDs GENERATOR
MONITOR (GENMON) AND GENERATOR
COMMAND (GENCMD)
Yes
• Connect a fused jumper wire between generator
C102A-1, circuit CDC15 (VT), harness side and No
generator C102A-2, circuit CDC10 (BU/OG), GO to C12 .
harness side.

• Monitor the GENMON and GENCMD PIDs
while performing a wiggle test on the generator
harness.
• Does the GENMON PID read within 5% of
the GENCMD PID?
CIRCUIT FOR DAMAGE OR AN OPEN
Yes
• Disconnect: Fused Jumper Wire.
• Disconnect: PCM C175B (2.5L or 3.0L). No
• Disconnect: PCM C175E (3.5L). REPAIR circuit CDC10 (BU/OG). CLEAR
• Inspect the following harness connectors for the DTCs. REPEAT the self-test. TEST the
damaged or pushed-out pins: system for normal operation.
♦ PCM C175B-53, circuit CDC10
(BU/OG) (2.5L or 3.0L)
♦ PCM C175E-13, circuit CDC10
(BU/OG) (3.5L)
♦ Generator C102B-2, circuit CDC10
(BU/OG)
• For 2.5L or 3.0L engines, measure the resistance
between PCM C175B-53, circuit CDC10
(BU/OG), harness side and generator C102A-2,
circuit CDC10 (BU/OG, harness side.

• For 3.5L engines, measure the resistance

between PCM C175E-13, circuit CDC10
(BU/OG), harness side and generator C102A-2,
circuit CDC10 (BU/OG) harness side.
• Are the connectors and pins free of damage

and is the resistance less than 5 ohms?
Yes
• Disconnect: Generator C102A (if not previously
disconnected). No
• Disconnect: PCM C175B (2.5L or 3.0L). REPAIR circuit CDC10 (BU/OG). CLEAR
• Disconnect: PCM C175E (3.5L). the DTCs. REPEAT the self-test. TEST the
• Measure the resistance between the generator system for normal operation.
C102A-2, circuit CDC10 (BU/OG), harness side
and ground.

C10 CHECK THE CHARGING SYSTEM
CIRCUITS FOR INTERMITTENT FAULTS
Yes
• Connect: Generator C102A. INSTALL a new generator. REFER to
• Connect: PCM C175B (2.5L or 3.0L). Generator - 2.5L , Generator - 3.0L or
• Connect: PCM C175E (3.5L). Generator - 3.5L in this section. CLEAR the
• Ignition ON. DTCs. REPEAT the self-test. TEST the
• Clear all DTCs. system for normal operation.

• Start the engine and let the engine run for 5

minutes. No
• Retrieve Continuous Memory Diagnostic The fault is not present at this time. This may
Trouble Codes (CMDTCs) from all modules. indicate an intermittent fault. CARRY OUT a
• Did any charging system DTC get stored into wiggle test on the charging system circuits to
memory? try and RECREATE the concern. CHECK
generator connections for corrosion, loose
connections and/or bent terminals. REPAIR as
necessary. CLEAR the DTCs. REPEAT the
operation.
AND PCM FOR A SHORT TO VOLTAGE
Yes
• Disconnect: PCM C175B (2.5L or 3.0L). 303-14A for 2.5L engines, Section 303-14B
• Disconnect: PCM C175E (3.5L). for 3.0L engines or Section 303-14C for 3.5L
• Ignition ON. engines. CLEAR the DTCs. REPEAT the
• Measure the voltage between generator self-test. TEST the system for normal
C102A-2, circuit CDC10 (BU/OG), harness side operation.
and ground.
No
REPAIR circuit CDC10 (BU/OG). CLEAR
• Does voltage read 0 volt?

C12 INSPECT GENERATOR CONNECTORS
AND CIRCUITS
Yes
• Disconnect: PCM C175B. 303-14A for 2.5L engines, Section 303-14B
• Inspect the following connector pins for damage for 3.0L engines or Section 303-14C for 3.5L
and/or corrosion: engines. CLEAR the DTCs. REPEAT the
♦ PCM C175B-66, circuit GD113 self-test. TEST the system for normal
(BK/YE) operation.
♦ Generator C102A-1, circuit CDC15
(VT) No
♦ Generator C102A-2, circuit CDC10 REPAIR high resistance or loose connections
(BU/OG) in the affected circuit(s). CLEAR the DTCs.
• Are the connectors and circuits OK? REPEAT the self-test. TEST the system for
normal operation.
Pinpoint Test D: DTC P0625 or P0626

Normal Operation
The PCM monitors the generator output via the GENMON circuit (generator field terminal circuit). If the
PCM cannot read the GENMON circuit due to an open or short to ground, when the engine rises above
approximately 2,000 rpm, the generator will default to a steady voltage of approximately 13.5 volts and the
PCM will send a request to the Instrument Cluster (IC) to illuminate the charging system warning indicator. A
GENMON duty cycle of 3% or less indicates a short to ground fault is present and will result in DTC P0625
setting in the PCM. A GENMON duty cycle of 98% or more indicates an open or short to voltage fault is
present and will result in DTC P0626 setting in the PCM.
• DTC P0625 (Generator Field Terminal Circuit Low) - If the GENMON circuit is shorted to ground,
the A sense circuit is open or the B+ circuit is open, the PCM will set this DTC. This DTC can also be
set by a faulted PCM or generator.
• DTC P0626 (Generator Field Terminal Circuit High) - If the GENMON circuit is open or shorted to
power, the PCM will set this DTC. This DTC can also be set by a faulted PCM or generator.

• Fuse
• Engine, generator and battery grounds
• Battery
• Generator
• PCM
PINPOINT TEST D: DTC P0625 OR P0626

D1 CHECK THE BATTERY CONDITION
Yes
• Refer to Section 414-01 and carry out Pinpoint GO to D2 .
Test A: Battery Condition Test to determine if
the battery can hold a charge and is OK for use. No
• Does the battery pass the condition test? INSTALL a new battery. REFER to Section
414-01 . CLEAR the DTCs. REPEAT the
operation.
D2 CHECK THE GENERATOR B+
CONNECTION
Yes
• Inspect generator C102B, circuit SDC14 (RD),
harness side. Connection should be tight. No
• Inspect generator radial adapter connection on TIGHTEN or INSTALL a new C102B (B+
rear of generator. Connection should be tight. nut) and/or radial arm adapter as needed.
• Measure the voltage between generator C102B, REFER to Specifications in this section.
circuit SDC14 (RD) and ground. VERIFY the fusible link is OK. If the fusible
link is OK, REPAIR circuit SDC14 (RD). If

not OK, REFER to the Wiring Diagrams

manual to identify the possible causes of the
circuit short. CLEAR the DTCs. REPEAT the
operation.
• Are the generator C102B and radial arm

adapter connections tight and does the
generator B+ measure battery voltage?
D3 CHECK THE VOLTAGE DROP IN THE B+
CIRCUIT
Yes
• Start the engine. For DTC P0625, GO to D4 .
• With the engine running at idle, headlamps on
and blower on high, measure the voltage drop For DTC P0626, GO to D6 .
between generator B+ C102B, circuit SDC14
(RD) and the positive battery terminal. No
INSPECT circuit SDC14 (RD), radial arm
adapter and the positive battery cable for loose
connections, physical damage or wire
corrosion. REPAIR as necessary. CLEAR the
• Carry out a wiggle test of the generator wiring

and connections while measuring voltage drop.
D4 A SENSE CIRCUIT LOAD TEST
Yes
NOTICE: The following step uses a test light GO to D5 .
to simulate normal circuit loads. Use only the
test light recommended in the Special Tools No
table at the beginning of this section. To avoid VERIFY Battery Junction Box (BJB) fuse 17
connector terminal damage, use the Flex (10A) is OK. If OK, REPAIR circuit SBB17
Probe Kit for the test light probe connection (RD). If not OK, REFER to the Wiring
to the vehicle. Do not use the test light probe Diagrams manual to identify the possible
directly on any connector. causes of the circuit short. CLEAR the DTCs.
NOTE: This step puts a load on the A sense normal operation.
circuit. If there are corroded or loose
connections, loading the circuit may help show
the fault. A 250-350 mA incandescent 12-volt
test lamp is required for this step. This circuit
will not be loaded properly using an LED-style
test lamp.
• Ignition OFF.
• Disconnect: Generator C102A .
PINPOINT TEST D: DTC P0625 OR P0626 5440

• Ignition ON.
check for voltage at C102A-3, circuit SBB17
(RD), harness side.

D5 CHECK CIRCUIT CDC15 (VT) FOR
DAMAGE OR A SHORT TO GROUND
Yes
• Disconnect: PCM C175B (2.5L or 3.0L).
• Disconnect: PCM C175E (3.5L). No
• Inspect the following harness connectors for REPAIR the connector(s) and/or circuit
damaged or pushed-out pins: CDC15 (VT). CLEAR the DTCs. REPEAT
♦ PCM C175B-14, circuit CDC15 (VT) the self-test. TEST the system for normal
(2.5L or 3.0L) operation.
♦ PCM C175E-26, circuit CDC15 (VT)
(3.5L)
♦ Generator C102A-1, circuit CDC15
(VT)
• Measure the resistance between generator
C102A-1, circuit CDC15 (VT), harness side and
ground.

and is the resistance greater than 10,000
ohms?
D6 CHECK THE GENERATOR B+ RESISTANCE
Yes
• NOTE: Failure to disconnect the battery will
result in false resistance readings. No
• Disconnect the battery. Refer to Section 414-01 . INSTALL a new generator. REFER to
• Disconnect: Generator C102B. Generator - 2.5L , Generator - 3.0L or
• Measure the resistance between generator Generator - 3.5L in this section. CLEAR the
C102B, component side and the generator DTCs. REPEAT the self-test. TEST the

housing. system for normal operation.
• Is the resistance greater than 25K ohms?

D7 CHECK THE RESISTANCE OF THE
VOLTAGE REGULATOR INTERNAL CIRCUITS
TO GROUND
D8 .
• Measure the resistance between generator No
C102A, component side and ground. Refer to the INSTALL a new generator. REFER to
following table. Generator - 2.5L , Generator - 3.0L or
Generator - 3.5L in this section. CLEAR the
Pin Expected Resistance

1 Greater than 10K ohms
• Are the resistance values as indicated?

D8 CHECK CIRCUIT CDC15 (VT) FOR
DAMAGE OR AN OPEN
Yes
• Disconnect: PCM C175B (2.5L or 3.0L).
• Disconnect: PCM C175E (3.5L). No
• Inspect the following harness connectors for REPAIR the connector(s) and/or circuit
damaged or pushed-out pins: CDC15 (VT). CLEAR the DTCs. REPEAT
♦ PCM C175B-14 (2.5L or 3.0L), circuit the self-test. TEST the system for normal
CDC15 (VT) operation.
♦ PCM C175E-26 (3.5L), circuit CDC15
(VT)
♦ Generator C102A-1, cirDC15 (VT)
• For 2.5L or 3.0L engines, measure the resistance
between PCM C175B-14, circuit CDC15 (VT),
harness side and generator C102A-1, circuit
CDC15 (VT), harness side.
• For 3.5L engines, measure the resistance
between PCM C175E-26, circuit CDC15 (VT),
harness side and generator C102A-1, circuit
CDC15 (VT), harness side.
and is the resistance less than 5 ohms?

D9 CHECK CIRCUIT CDC15 (VT) FOR A SHORT

TO POWER
Yes
• Connect the battery. Refer to Section 414-01 . REPAIR the connector(s) and/or circuit
• Ignition ON. CDC15 (VT). CLEAR the DTCs. REPEAT
• Measure the voltage between generator the self-test. TEST the system for normal
C102A-1, circuit CDC15 (VT), harness side and operation.
ground.
No
GO to D10 .
• Is there any voltage present?

D10 COMPARE THE PCM PIDs GENERATOR
MONITOR (GENMON) AND GENERATOR
COMMAND (GENCMD)
Yes
• Ignition OFF. INSTALL a new generator. REFER to
• Connect: PCM C175B (2.5L or 3.0L). Generator - 2.5L , Generator - 3.0L or
• Connect: PCM C175E (3.5L). Generator - 3.5L in this section. CLEAR the
• Connect a fused jumper wire between generator DTCs. REPEAT the self-test. TEST the
C102A-1, circuit CDC15 (VT), harness side and system for normal operation.
generator C102A-2, circuit CDC10 (BU/OG),
harness side. No
GO to D11 .

• Using the active command, set the GENVDSD
PID to 14.0 volts.
• Monitor the GENMON and GENCMD PIDs
while carrying out a wiggle test on the generator
wiring harness.
• Does the GENMON PID read within 2% of
the GENCMD PID?
D11 CHECK FOR CORRECT PCM OPERATION
Yes
• Disconnect: Fused Jumper Wire. 303-14A for 2.5L engines, Section 303-14B
• Check the PCM harness, generator harness, PCM for 3.0L engines or Section 303-14C for 3.5L
component side and generator component side engines. CLEAR the DTCs. REPEAT the

connectors for: self-test. TEST the system for normal

• Connect the PCM and/or generator connectors. No
Make sure the connectors seat correctly. The system is operating correctly at this time.
is still present. or corroded connector. CLEAR the DTCs.
• Is the concern still present? REPEAT the self-test. TEST the system for
normal operation.
Pinpoint Test E: DTC P065B
Normal Operation
With the engine running, the PCM expects to receive a valid generator monitor (GENMON) signal with a
duty cycle greater than 5% and less than 98%. The PCM also monitors the state of the generator command
(GENCMD) signal line to make sure it is not stuck high or stuck low. If the GENMON or GENCMD signal
fluctuates between out-of-valid range, or stuck high, or stuck low, or some combination and normal, a DTC
will be set. When engine speed rises above approximately 2,000 rpm, the generator will default to a steady
voltage of approximately 13.5 volts and the PCM will send a request to the Instrument Cluster (IC) to
illuminate the charging system warning indicator lamp.
• DTC P065B (Generator Control Circuit Range/Performance) - If the input frequency was
continuously less than 80 Hz or more than 200 Hz the PCM will set this DTC. Additionally, if the
signal shows a faulted condition that is happening in a fluctuating manner, the PCM will track the
fluctuations between faulted and normal conditions. If the fluctuations occur frequently within a short
amount of time, this DTC will also be set.

• Generator
• PCM
PINPOINT TEST E: DTC P065B
NOTE: Make sure battery voltage is greater than 12.2 volts prior to carrying out this pinpoint test.
Test Step Resul/ Action to Take

E1 CHECK THE BATTERY CONDITION
Yes
• Refer to Section 414-01 and carry out Pinpoint Test A: GO to E2 .
Battery Condition Test to determine if the battery can
hold a charge and is OK for use. No
• Does the battery pass the condition test? INSTALL a new battery. REFER to
Section 414-01 . CLEAR the DTCs.


E2 CHECK THE GENERATOR CONNECTIONS
Yes
• Inspect generator C102A connection. Connector
should be installed correctly and tight. No
• Disconnect: Generator C102A. TIGHTEN or INSTALL a new C102B
• Inspect generator C102A for bent and/or pushed-out (B+ nut) and/or radial arm adapter as
pins. needed. REFER to Specifications in this
• Inspect generator C102B, B+ circuit SDC14 (RD) and section. VERIFY the fusible link is OK.
radial arm connection(s). Connection should be tight. If the fusible link is OK, REPAIR circuit
• Measure the battery voltage. SDC14 (RD). If not OK, REFER to the
operation.
• Measure the voltage between generator C102B, B+

circuit SDC14 (RD) and ground.
• Are the generator C102B and radial arm adapter

connections tight and does the generator B+
measure battery voltage?
E3 A SENSE CIRCUIT LOAD TEST
Yes
NOTICE: The following step uses a test light to GO to E4 .
simulate normal circuit loads. Use only the test
light recommended in the Special Tools table at the No
beginning of this section. To avoid connector VERIFY Battery Junction Box (BJB)
terminal damage, use the Flex Probe Kit for the fuse 17 (10A) is OK. If OK, REPAIR
test light probe connection to the vehicle. Do not circuit SBB17 (RD). If not OK, REFER
use the test light probe directly on any connector. to the Wiring Diagrams manual to
identify the possible causes of the circuit
NOTE: This step puts a load on the A sense circuit. If short. CLEAR the DTCs. REPEAT the
there are corroded or loose connections, loading the self-test. TEST the system for normal
circuit may help show the fault. A 250-350 mA operation.
incandescent 12-volt test lamp is required for this step.
This circuit will not be loaded properly using an
LED-style test lamp.
PINPOINT TEST E: DTC P065B 5445

• Ignition ON.
• Using a 12-volt test lamp connected to ground, check
for voltage at C102A-3, circuit SBB17 (RD), harness
side.

E4 CHECK THE PCM GENERATOR MONITOR
FREQUENCY (GENMON_HZ) PID
Yes
• Connect: Generator C102A.
• NOTE: Many of the PCM PIDs selected will be GO to E5 .
monitored later in this pinpoint test.
• Select and monitor the following PCM PIDs:
♦ Generator Voltage Desired (GENVDSD)
♦ Generator Monitor Frequency
(GENMON_HZ)
• Monitor the GENMON_HZ PID.
• Does the PID read between 80-200 Hz?
E5 CHECK THE PCM GENERATOR MONITOR
FREQUENCY (GENMON_HZ) PID WITH
GENERATOR C102A DISCONNECTED
Yes
• Monitor the GENMON_HZ PID. GO to E6 .
• Does the PID read between 0-2 Hz?
E6 CHECK GENERATOR CIRCUITRY
Yes
• Ignition OFF. INSPECT the harness for wire to wire
• NOTICE: This pinpoint test step directs testing shorts or insulation chaffing, mis-pinned
circuits using a back-probe method. Use the special connectors and correct wire colors and
back-probe tool specified in the tool list in this REPAIR generator circuit CDC15 (VT)
section. Do not force test leads or other probes into as needed. CLEAR the DTCs. REPEAT
connectors. Adequate care must be exercised to the self-test. TEST the system for normal
avoid connector terminal damage while making operation.
sure that good electrical contact is made with the
circuit or terminal. Failure to follow these No
instructions may cause damage to wiring, INSTALL a new PCM. REFER to
terminals, or connectors and subsequent electrical Section 303-14A for 2.5L engines,
faults. Section 303-14B for 3.0L engines or
Section 303-14C for 3.5L engines.

• With PCM C175B (2.5L or 3.0L) or C175E (3.5L) CLEAR the DTCs. REPEAT the
connected, connect a fused jumper wire between PCM self-test. TEST the system for normal
C175B-14 (2.5L or 3.0L) or C175E-26 (3.5L), circuit operation.
CDC15 (VT) and ground by carefully back probing
the connector.
• Does the PID read 0 Hz?
E7 MONITOR THE PCM PID GENERATOR
MONITOR FREQUENCY (GENMON_HZ) WHILE
ACTIVATING THE GENERATOR VOLTAGE
DESIRED (GENVDSD) PID
Yes
• Connect a fused jumper wire between generator Generator - 2.5L , Generator - 3.0L or
C102A-1, circuit CDC15 (VT), harness side and Generator - 3.5L in this section. CLEAR
generator C102A-2, circuit CDC10 (BU/OG), harness the DTCs. REPEAT the self-test. TEST
side. the system for normal operation.
No
INSTALL a new PCM. REFER to
Section 303-14A for 2.5L engines,
Section 303-14B for 3.0L engines or
Section 303-14C for 3.5L engines.
self-test. TEST them for normal
operation.
• With the engine running at idle, set the active
command GENVDSD PID to 14 volts.
• Does the GENMON_HZ PID read between 120-130
Hz?
E8 CHECK THE PCM GENERATOR COMMAND
LINE FAULT (GENCMD_LF) PID
Yes
• With the engine running and all selectable loads OFF, INSTALL a new generator. REFER to
monitor the PCM PID GENCMD_LF. Generator - 2.5L , Generator - 3.0L or
• Does the PCM PID GENCMD_LF fluctuate from Generator - 3.5L in this section. CLEAR
YES FAULT to NO FAULT? the DTCs. REPEAT the self-test. TEST
No
The fault is not present at this time. This
may indicate an intermittent fault.
CARRY OUT a wiggle test on the
charging system circuits to try and
RECREATE the concern. CHECK
generator connections for corrosion,
loose connections and/or bent terminals.
REPAIR as necessary. CLEAR the

Pinpoint Test F: The Generator is Noisy
Ro Wiring Diagrams Cell 12 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Charging System for schematic
Normal Operation
The generator is belt-driven by the engine accessory drive system. There are several sources of generator
noise which include: bearing noise, electrical fault noise, generator or belt pulley misalignment. A generator
with certain types of diode or stator failures may also produce an audible noise.

• Accessory drive belt
• Loose bolts/brackets
• Generator/pulley
PINPOINT TEST F: THE GENERATOR IS NOISY

F1 CHECK FOR ACCESSORY DRIVE
BELT NOISE AND LOOSE MOUNTING
BRACKETS
Yes
• Check the accessory drive belt and
tensioner for damage and correct No
installation. Refer to the appropriate REPAIR as necessary. Refer to the appropriate section
section in Group 303 for the procedure.. in Group 303 for the procedure. for diagnosis and
• Check the accessory mounting brackets testing of the accessory drive system. TEST the
and generator pulley for looseness or system for normal operation.
misalignment.
• Is the accessory drive OK?
F2 CHECK THE GENERATOR
MOUNTING
Yes
• Check the generator mounting for loose GO to F3 .
bolts or misalignment.
• Is the generator mounted correctly? No
REPAIR as necessary. TEST the system for normal
operation.
F3 CHECK THE GENERATOR FOR
NOISE
Yes
• With the engine running, use a INSTALL a new generator. REFER to Generator -
stethoscope or equivalent listening 2.5L , Generator - 3.0L or Generator - 3.5L in this
device to probe the generator and the section. CLEAR the DTCs. REPEAT the self-test.
accessory drive area for unusual TEST the system for normal operation.
mechanical noise.
• Is the generator the noise source? No

REFER to Section 303-00 to diagnose the source of

the engine noise.
Pinpoint Test G: Radio Interference
Normal Operation
The generator radio suppression equipment reduces interference transmitted through the speakers by the
vehicle electrical system.

• Generator
• In-vehicle entertainment system
PINPOINT TEST G: RADIO INTERFERENCE
NOTE: If the OEM audio unit has been replaced with an aftermarket unit, the vehicle may not pass this test.
Return the vehicle to OEM condition before following this pinpoint test.
NOTE: If the engine is operated at greater than 2,000 rpm momentarily, the generator will self-excite. Make
sure when the generator is disconnected the engine rpm stays below 2,000 rpm. If it does rise above 2,000
rpm, turn the ignition to the off position and start the test over again.
NOTE: Inspect for any after market accessories that have been added to the vehicle. Check the wiring for
these accessories and be sure they have not been attached to the generator circuits and are positioned away
from the generator wiring.

G1 VERIFY THE GENERATOR IS
THE SOURCE OF THE RADIO
INTERFERENCE
Yes
• Start the engine and allow the REFER to Section 415-00 for diagnosis and testing of the
engine to idle. in-vehicle entertainment system.
• Tune the audio unit to a station
where the interference is present. No
• Ignition OFF. INSTALL a new generator. REFER to Generator - 2.5L ,
• Disconnect: Generator C102B. Generator - 3.0L or Generator - 3.5L in this section. CLEAR
• Start the engine and allow the the DTCs. REPEAT the self-test. TEST the system for normal
engine to idle, determine if the operation.
interference is still present.
• Is the interference present
with the generator
disconnected?
PINPOINT TEST F: THE GENERATOR IS NOISY 5449

PINPOINT TEST G: RADIO INTERFERENCE 5450

SECTION 414-00: Charging 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop
System Manual
REMOVAL AND
INSTALLATION
Generator - 2.5L

1 8620 Front End Accessory Drive (FEAD) belt
2 10C392 Generator upper air duct
3 W500004 Generator upper air duct screws (3 required)
4 W520414 Generator stud nut (2 required)
5 - Generator electrical connector (part of 12B637)
6 - B+ protective cover (part of 14A280)
7 W705790-S Generator B+ terminal nut
8 - Generator B+ cable (part of 14A280)
9 10300 Generator
10 W709489 Generator stud (2 required)
11 10C392 Generator lower air duct
12 W500130 Generator bolt
13 10329 Radial arm adapter
14 - Radial arm adapter nut (part of 10329)
15 - Radial arm adapter cap (part of 10329)
Removal
NOTICE: Do not allow any metal object to come i the generator housing and internal diode cooling fins.
A short circuit may result and burn out the diodes. Failure to follow this instruction may result in
component damage.
NOTE: The radial arm adapter is a serviceable item. Do not replace the generator if the radial arm adapter is
the only concern.
100-02 .
2. Disconnect the battery. For additional information, refer to Section 414-01 .
Generator - 2.5L 5451

3. Remove the 4 RH lower splash shield screws.
4. Remove the 6 pushpins and the RH lower splash shield.
5. Rotate the Front End Accessory Drive (FEAD) belt tensioner clockwise and position the accessory
drive belt aside.
6. Working from the top of the vehicle, press the locking tab to release the generator lower air duct from
the generator and remove the lower air duct.
7. Remove the battery harness locator from the lower generator stud bolt.
8. Remove the lower generator bolt.
9. Remove the 2 generator stud nuts.
10. Position the generator B+ protective cover aside and remove the generator B+ terminal nut.
11. Position the generator B+ cable aside.
12. Disconnect the generator electrical connector.
13. Remove the 2 generator studs and remove the generator.
14. Remove the 3 screws and the generator upper air duct.
Installation
1. Position the generator upper air duct and install the 3 screws.
2. Working from the top of the vehicle, position the generator and install the generator upper stud
hand-tight.
3. Install the generator lower stud hand-tight.
4. Install the generator B+ cable and install the generator B+ terminal nut.
5. Connect the generator electrical connector.
6. Position the generator B+ protective cover on the B+ terminal.
7. Working from under the vehicle, install the lower generator bolt hand-tight.
8. Working from the top of the vehicle, tighten the 2 generator studs to 24 Nm (18 lb-ft).
9. Tighten the 2 generator stud nuts to 47 Nm (35 lb-ft).
10. Tighten the generator bolt to 47 Nm (35 lb-ft).
11. Push the lower air duct onto the upper air duct until the locking tab is engaged.
12. Position the RH lower splash shield and install the 6 pushpins.

13. Position the RH wheel splash shield and install the 4 screws.
14. Position the harness locator on the generator stud.
15. Connect the battery. For additional information, refer to Section 414-01 .
16. Rotate the FEAD belt tensioner clockwise and position the accessory drive belt on the pulley.

System Manual
REMOVAL AND
INSTALLATION
Generator - 3.0L

1 W706414 Generator B+ terminal nut
2 - Generator B+ terminal (part of 14B060)
4 W707669 Generator stud bolt
5 W704747 Generator bolts (2 required)
6 10300 Generator
1. Remove the A/C compressor. For additional information, refer to Section 412-01 .
start="3">
• Position the generator protective cover aside, remove the nut and position the generator B+ terminal aside.
5. Remove the 3 bolts and the generator.



System Manual
REMOVAL AND
INSTALLATION
Generator - 3.5L
Material
Item Specification
or equivalent

1 W712609 Generator stud
2 W520414 Generator stud nut
3 W709986 Generator bolt
5 10300 Generator
8 - Pin-type retainer, wiring harness
9 10329 Radial arm adapter
10 - Radial arm adapter nut (part of 10329)
11 - Radial arm adapter cap (part of 10329)

NOTE: The radial arm adapter is em. Do not replace the generator if the radial arm adapter is the only
concern.
1. Remove the A/C compressor. For additional information, refer to Section 412-01 .
3. Position the generator protective cover aside, remove the nut and position the generator B+ terminal
aside.

• Detach the pin-type retainer and wiring harness.
5. Remove the oil filter.

• Lubricate the oil filter seal with clean engine oil before installation.
6. Position the engine wiring harness aside.
7. Remove the generator stud nut.

8. Remove the generator bolt and the generator.


SECTION 414-01: Battery, Mounting and Cables
Workshop Manual
Item Specification
Battery
Cold Cranking Amps (CCA) 390 CCA - 2.5L hybrid vehicles
measured at -18°C (0°F) 500 CCA - All other vehicles

Voltage 12 volts

Battery cable body ground terminal bolt 12 - 106
Battery cable starter motor B+ terminal nut 12 - 106
Battery cable terminal nuts 7 - 62
Battery cable transaxle ground terminal bolt/nut 17 - 150
Battery hold-down bracket bolt/nut 10 - 89
Battery Junction Box (BJB) cable terminal nut 9 - 80
Battery tray bolt/nut 9 80
Generator B+ terminal nut 12 - 106
Starter motor solenoid wire terminal nut 5 - 44
Tie-rod end nut 48 35 -



Workshop Manual
Battery and Cables
Vehicles are equipped with a 12-volt, maintenance-free battery.
The battery and cable system consists of the following components:
• Battery
• Battery cable assembly
• Battery tray
The battery is a 12V DC source connected in a negative ground system. The battery case is sealed with 2 vent
holes to release gases. The battery has 3 major functions:
• Engine cranking power source

• Voltage stabilizer for the electrical system
• Temporary power source when electrical loads exceed the generator output current
Ford Motor Company strongly recommends that lead-acid batteries be returned to an authorized recycling
facility for disposal.
Battery and Cables 5460

SECTION 414-01: Battery, Mounting and 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid
Cables Workshop Manual
Battery Eye Operation
The battery eye indicates the state-of-charge of the battery by responding to the specific gravity of a single
battery cell electrolyte. The battery eye has a viewing plate, 2 colored balls of different specific gravity and a
small passage. As the state-of-charge and specific gravity changes, the balls change their position in the
passageway and subsequently display a different color in the viewing eye. The primary purpose of the battery
is to be a quick indicator of state-of-charge for assembly plants and dealership pre-delivery processes.
The color of the battery eye indicates the approximate state-of-charge.
• Red - indicates low state-of-charge.

• Yellow/Black - indicates between high and low state-of-charge.
• Green - indicates high state-of-charge.
• No color can occur after the battery has been in service for several years and some of the plate
material has coated the balls.
• A clear battery eye can occur if the battery case becomes damaged and the electrolyte has fallen
below the plates.
NOTE: The battery eye may remain red for a period of time (up to several days), even after the battery is
fully charged, because the acid is not yet fully mixed.
Do not install a new battery based solely on the indication of the battery eye. The battery eye color simply
indicates the battery state-of-charge, not its condition. For example, a red or yellow/black battery eye usually
indicates the battery is discharged, not defective. If the battery eye indicates the battery may be discharged, it
is necessary to recharge the battery before testing its condition.
Charging a Battery
Batteries discharge while the vehicle is on the dealer lot or parked by the customer for an extended period of
time due to normal parasitic key-off loads. Also, vehicles still in dealer inventory or in long-term storage may
be driven short distances with heavy electrical loads. Over a period of time (30 days or more), this could result
in vehicles having shallow or deeply discharged batteries.
• Deeply discharged - A battery that is drained over a prolonged period of time, such as an unsold
vehicle or a vehicle in storage, to the point the battery is dead.
• Shallow discharge - A battery that is drained by leaving an accessory on for several hours or a few
days and has a very low charge.
The vehicle charging system is designed to supply the electrical power needed to maintain the battery near full
charge during normal vehicle use. The charging system is not capable of bringing a deeply discharged battery
back to near fuln a short amount of time such as allowing the vehicle to idle for 15 minutes to "recharge the
battery". Discharged batteries should be charged using an external charger.
NOTE: Battery chargers have improved greatly with the addition of the new generation pulse chargers. These
chargers pulse current into the battery, breaking down the sulfation layer on the battery plates and generally
reduce charging times to less than an hour.

NOTE: Cold batteries will not readily accept a charge. Therefore, batteries should be allowed to warm to
approximately 5°C (41°F) before charging. This may require 4 to 8 hours at room temperature.
The following chart summarizes 2 recommended methods of charging.
Type of Battery
Discharge Pulse Charger Standard Charger
Deeply discharged Follow directions supplied with the 2 to 8 hours and may take up to an hour to
pulse charger accept initial charge
Shallow discharge 45 minutes to an hour charge 2 hours below (40A) on manual setting or
medium automatic setting

Inspection And Verification
• Battery • Battery
• Battery cables
mounting • Battery
posts
4. If the fault is not visually evident, GO to Pinpoint Test A in the Pinpoint Test procedure.

Pinpoint Test
Special Tool(s)
GR 1 190 V3.0 Intelligent Diagnostic

Charger
Pinpoint Test A: Battery Condition Test
Normal Operation
Battery condition is determined by measuring battery terminal voltage after a specific discharge current is
applied for a specified time period.

• Battery charge
• Battery
PINPOINT TEST A: BATTERY CONDITION TEST

A1 TEST THE BATTERY
CONDITION
Yes
NOTE: A red test-eye indicates RETURN the battery to service.
the battery is discharged, not
necessarily defective. No
If the analyzer reads REPLACE BATTERY or
NOTE: Failure to fully charge REPLACE-BAD CELL, INSTALL a new battery. REFER to
the battery before retesting may Battery in this section.
cause false readings.
• Verify the battery condition using

the Intelligent Diagnostic
Charger.
• Is the battery OK?
Pinpoint Test 5464

PINPOINT TEST A: BATTERY CONDITION TEST 5465

Component Test
Battery - Drain Tests
NOTICE: To prevent damage to the meter, do not crank the engine or operate accessories that draw
more than 10A.
NOTE: No factory-equipped vehicle should have more than a 50 mA (0.050 amp) draw.
Check for current drains on the battery in excess of 50 mA (0.050 amp) with all the electrical accessories off
and the vehicle at rest for at least 40 minutes. Current drains can be tested with the following procedure.
NOTE: Many electronic modules draw 10 mA (0.010 amp) or more continuously.
NOTE: Typically, a drain of approximately 1 amp is attributed to an engine compartment lamp, glove
compartment lamp or interior lamp staying on continually. Other component failures or wiring shorts are
located by selectively pulling fuses to pinpoint the location of the current drain. When the current drain is
found, the meter reading falls to an acceptable level. If the drain is still not located after checking all the fuses,
it may be due to the generator. Disconnect the generator and retest.
NOTE: To curately test the drain on a battery, an in-line ammeter must be used between the negative battery
post and its respective cable. Use of a test lamp or voltmeter is not an accurate method.
1. Drive the vehicle at least 5 minutes and over 48 km/h (30 mph) to turn on and activate the vehicle
systems.
2. After driving the vehicle and before testing, make sure the junction box(es)/fuse panel(s) is accessible
without turning on the interior lights or the underhood lights.
3. Allow the vehicle to sit with the key out of the ignition for at least 40 minutes to allow the modules to
time out/power down.
4. Connect a fused jumper wire (30A) between the negative battery cable and the negative battery post
to prevent modules from resetting.
5. Disconnect the negative battery cable from the negative battery post without breaking the connection
of the jumper wire.
6. NOTE: It is very important that continuity is not broken between the battery and the negative battery
cable when connecting the meter. If this happens, the entire 40-minute procedure must be repeated.
Component Test 5466

Connect the battery tester between the negative battery cable and the post. The meter must be capable
of reading milliamps and should have a 10-amp capability.
7. NOTE: If the meter settings need to be switched or the test leads need to be moved to another jack,
the jumper wire must be reinstalled to avoid breaking continuity.
Remove the jumper wire.
8. Note the amperage draw. Draw varies from vehicle to vehicle depending on the equipment package.
Compare to a similar vehicle for reference.
NOTE: If the vehicle sits for an extended period of time and the battery drains, there is the possibility of a
control module staying alive and not going into sleep mode. If a module does stay alive, it can also result in
battery drain. If a module is suspect, isolate individual modules by disconnecting each module one at a time
and note if the excessive draw goes away.
NOTE: For vehicles equipped with aftermarket bodies or boxes which contain electrical connections,
disconnect the aftermarket to factory connections to isolate the body from the chassis.
9. If the current draw is excessive, remove the fuses from the Battery Junction Box (BJB) one at a time
and note the current drop. When the current level drops to an acceptable level after removing a fuse,
the circuit containing the excessive draw has been located. The excessive draw can be isolated by
continuing to pull sub system fuses. Do not reinstall the fuses until testing is finished. To correctly
isolate each of the circuits, all of the fuses may need to be removed, then install one fuse and note the
amperage draw, remove the fuse and install the next fuse. Continue this process with each fuse.
• Once the main circuit is identified, continue to remove the fuses from the Smart Junction Box
(SJB) one at a time and note the current reading. Do not reinstall the fuses until testing is
finished. To correctly isolate each of the circuits, all of the fuses may need to be removed,
then install one fuse and note the amperage draw, remove the fuse and install the next fuse.
Continue this process with each fuse.
10. Check the wiring diagrams for any circuits that run from the battery without passing through the BJB
or the SJB . If the current draw is still excessive, disconnect these circuits until the draw is found.
Also, disconnect the generator electrical connections and retest if the draw cannot be located. The
generator may be internally shorted, causing the current drain.
Component Test 5467

Component Test 5468

Battery Disconnect
WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint system (SRS) component and before servicing, removing,
installing, adjusting or striking components near the front or side impact sensors or the restraints
control module (RCM). Nearby components include doors, instrument panel, console, door latches,
strikers, seats and hood latches. Refer to the Description and Operation portion of Section 501-20B for
location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the
battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power
supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death
in the event of an accidental deployment.
WARNING: Battery posts, terminals and related accessories contain lead and lead components.
Wash hands after handling. Failure to follow these instructions may result in serious personal injury.
NOTE: When the battery (or PCM) is disconnected and connected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The charging system set point may also vary. The
vehicle may need to be driven to relearn its strategy.
1. On hybrid vehicles, remove the Air Cleaner (ACL) assembly. For additional information, refer to
Section 303-12A .
2. NOTE: When disconnecting the battery ground cable to interrupt power to the vehicle electrical
system, disconnect the battery ground cable only. It is not necessary to disconnect the positive battery
cable.
Disconnect the battery ground terminal.
• To connect, tighten to 7 Nm (62 lb-in).
3. Disconnect the positive battery terminal.

• To connect, tighten to 7 Nm (62 lb-in).
4. To connect, reverse the disconnect procedure.
Battery Disconnect 5469

Battery Disconnect 5470

Battery and Battery Tray - Exploded View
Battery and Battery Tray, Hybrid Vehicles

1 - Battery hold-down bracket
2 - Battery hold-down bracket bolt
3 10655 Battery
4 W700430 Battery tray nut (4 required)
Battery and Battery Tray, All Other Vehicles
NOTE: 3.0L and 3.5L engine shown, 2.5L similar.
Battery and Battery Tray - Exploded View 5471

Part
1 10A687 Battery cover (3.0L and
3.5L only)
2 10655 Battery
3 - Battery hold-down bracket
bolt
4 - Battery hold-down bracket 5 W700430 Battery tray
nuts
6 W710610 Battery tray bolt
Battery and Battery Tray, All Other Vehicles 5472

Battery and Battery Tray, All Other Vehicles 5473

Battery
WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint system (SRS) component and before servicing, removing,
installing, adjusting or striking components near the front or side impact sensors or the restraints
control module (RCM). Nearby components include doors, instrument panel, console, door latches,
strikers, seats and hood latches. Refer to the Description and Operation portion of Section 501-20B for
location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the
battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power
supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death
in the event of an accidental deployment.
NOTE: When the battery (or PCM) is disconnected and connected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The charging system set point may also vary. The
vehicle may need to be driven to relearn its strategy.
1. Disconnect the battery. For additional information, refer to Battery Disconnect in this section.
2. Remove the bolt and the battery hold-down bracket.

3. If equipped, remove the battery heat shield.
4. Remove the battery.
Battery 5474
Battery 5475
Battery Tray
1. Remove the battery. For additional information, refer to Battery in this section.
2. Remove the battery tray fasteners.

• Hybrid vehicles use 4 nuts.
• All other vehicles use 1 bolt and 2 nuts.
3. Remove the battery tray.
Battery Tray 5476

Battery Cables - 2.5L
View 1 of 2
Part
1 - A/C compressor clutch field
electrical connector (part of
14B060)
2 - Wiring harness retainer (part
of 14B060)
3 - Starter motor solenoid wire
terminal (part of 14B060)
4 W705790 Starter motor solenoid wire
terminal nut
5 - Battery cable retainer (part of
14B060)
6 11N087 Starter solenoid terminal cover
7 - Battery cable starter solenoid
8 W706414 Battery cable starter solenoid
terminal nut
Battery Cables - 2.5L 5477

9 W520513 Battery cable transaxle ground

terminal nut
10 - Battery cable transaxle ground
11 - Automatic transaxle turbine
speed sensor connector (part
of 14B060)
12 - Automatic transaxle electrical
connector (part of 14B060)
13 - Battery cable in-line harness 14 - Battery Junction Box
electrical connector (part of (BJB) cable terminal
14B060) nut
15 - BJB terminal
16 W705936 Battery cable body ground
terminal bolt
17 - Battery cable body ground
18 14B060 Battery cables
View 2 of 2

21 - Battery cable locator (part of 14B060)
View 1 of 2 5478
100-02 .
2. Remove the battery tray. For additional information, refer to Battery Tray in this section.
3. Remove the bolt and position the battery cable body ground terminal aside.
4. Remove the nut and position the Battery Junction Box (BJB) cable terminal aside.
5. Disconnect the battery cable in-line harness connector from the engine compartment wiring harness
and position aside.
6. Release the 2 wiring harness retainers from the body.
7. Disconnect the A/C compressor clutch field electrical connector and position aside.
8. Release the wiring harness retainer from the intake manifold.
9. Remove the starter solenoid terminal cover.
10. Remove the nut and position the battery cable starter solenoid terminal aside.
11. Remove the nut and position the starter motor solenoid wire terminal aside.
12. Remove the nut and position the battery cable transaxle ground terminal aside.
13. Release the wiring harness retainer from the transaxle stud bolt.
14. Disconnect the transaxle electrical connector and position aside.
15. Disconnect the turbine speed sensor electrical connector and position aside.
aside.
17. Disconnect the generator electrical connector and move aside.
18. Release the 3 battery cable locators from the valve cover.
19. Remove the battery cables.
View 2 of 2 5479
View 2 of 2 5480
View 1 of 2
Part
1 - A/C compressor clutch field
14B060)
2 - Wiring harness locator (part of
14B060)
3 - Generator electrical connector (part
of 14B060)
4 - Generator B+ terminal (part of
14B060)
6 - Heated Oxygen Sensor (HO2S)
14B060)
7 - Automatic transaxle turbine speed
sensor connector (part of 14B060)
8 -

Automatic transaxle electrical

connector (part of 14B060)
9 - Battery cable in-line harness
14B060)
10 - Battery Junction Box (BJB) cable
terminal nut
11 - BJB terminal
12 W705936 Battery cable body ground terminal
bolt
Battery cable body ground
14 - Battery cable retainer (part of
14B060)
15 14B060 Battery cables
View 2 of 2

16 - Starter motor solenoid wire terminal (part of 14B060)
17 W705790 Starter motor solenoid wire terminal nut
18 11N087 Starter solenoid terminal cover
19 - Battery cable starter solenoid terminal (part of 14B060)
20 W706414 Battery cable starter solenoid terminal nut
21 W705790 Battery cable transaxle ground terminal nut
22 - Battery cable transaxle ground terminal (part of
14B060)
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Sec2 .
2. Remove the battery tray. For additional information, refer to Battery Tray in this section.
3. Remove the bolt and position the battery cable body ground terminal aside.
View 1 of 2 5482
4. Remove the nut and position the Battery Junction Box (BJB) cable terminal aside.
5. Disconnect the battery cable in-line harness connector from the engine compartment wiring harness
and position aside.
6. Release the 2 battery cable retainers from the body.
7. Disconnect the A/C compressor clutch field electrical connector and position aside.
8. Release the wiring harness locator from the generator mounting stud.
aside.
10. Disconnect the generator electrical connector and position aside.
11. Release the wiring harness locators from the valve cover.
12. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector electrical connector and position
aside.
13. Release the wiring harness locator from the transaxle stud bolt.
14. Disconnect the transaxle electrical connector and position aside.
15. Release the wiring harness locator from the transaxle stud bolt.
16. Disconnect the turbine speed sensor electrical connector and position aside.
17. Remove the starter solenoid terminal cover.
18. Release the battery cable retainer from the transaxle.
19. Remove the nut and position the battery cable starter solenoid terminal aside.
20. Remove the nut and position the starter motor solenoid wire terminal aside.
21. Remove the nut and position the battery cable engine ground terminal aside.
22. Remove the battery cables.
View 2 of 2 5483
View 2 of 2 5484
Special Tool(s)
Remover, Tie-Rod End

211-105 (T85M-3395-A
Component Connections
Part
1 - Generator terminal cover (part of 14300)
2 - A/C compressor electrical connector (part of 14300)
3 - Generator B+ terminal (part of 14300)
4 W706414 Generator B+ terminal nut - 12 Nm (106 lb-in)
5 - Generator electrical connector (part of 14300)
6 14300 Battery cable
7 - Transmission Control Module (TCM) electrical
8 - Battery cable transaxle ground terminal (part of 14300)
9 W503271 ansaxle ground terminal bolt - 10 Nm (89 lb-in)
10 -

Power steering pressure switch electrical connector (part

of 14300)
11 - Battery Junction Box (BJB) cable terminal (part of
14290)
12 W705790 BJB cable terminal nut - 9 Nm (80 lb-in)
13 W705936 Battery cable body ground terminal bolt - 12 Nm (106
lb-in)
14 - Battery cable body ground terminal (part of 14300)
15 - In-line electrical connectors (part of 14300)
16 W705790 Starter motor solenoid wire terminal nut - 5 Nm (44
lb-in)
17 - Starter motor solenoid terminal (part of 14300)
18 11N087 Starter motor solenoid terminal cover
19 - Battery cable starter motor B+ terminal (part of 14300)
20 W706414 Battery cable starter motor B+ terminal nut - 12 Nm
(106 lb-in)
Harness Retainers

1
Component Connections 5486


SECTION 414-03: High Voltage Traction Battery
Workshop Manual
Material

Instant Gel Adhesive WSK-M2G402-A4 -
TA-19
TA-25
Item Specification
High Voltage Traction Battery
Battery chemistry Nickel metal hydride
Battery system capacity 5.5 amp-hours
Standard voltage 275 volts
Low Voltage Battery
Voltage 12 volts

A/C compressor manifold and suction tube fitting nut 15 - 133
A/C evaporator inlet fitting nut 15 - 133
Battery Energy Control Module (BECM) nuts 9 - 80
Battery Pack Sensor Module (BPSM) nuTD valign="top" - 80
align="center">9
High-voltage Bussed Electrical Center (BEC) cover nuts 9 - 80
High-voltage BEC cover screws 9 - 80
High-voltage BEC nut 9 - 80
High-voltage cable shield nuts 9 - 80
High-voltage cable strain relief bolt 9 - 80
High-voltage cable connector and bracket assembly nuts 9 - 80
High-voltage cable connector and bracket assembly screw 6 - 53
High-voltage/high- current positive cable nut 15 lign="top"
align="center">133
High-voltage/high- and low-current negative cable nut 15 - 133
High-voltage/low-current cable nuts 4 - 35
High Voltage Traction Battery (HVTB) cable nuts 15 - 133
Harness Retainers 5487

HVTB cooling inlet duct nuts 6 - 53

HVTB ground strap-to-chassis bolt 12 - 106
HVTB mounting bolts 20 - 177
Hydraulic Control Unit (HCU) bracket bolts 23 17 -
Harness Retainers 5488

SECTION 414-03: High Voltage Traction 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid
Battery Workshop Manual
High-Voltage Traction Battery
service instructions, including instructions to depower the system. The high-voltage system utilizes
NOTICE: The High Voltage Traction Battery (HVTB) in a Hybrid Electric Vehicle (HEV) can be
affected and damaged by excessively high temperatures. The temperature in some body shop paint
booths can exceed 60°C (140°F). Therefore, during refinishing operations, the paint booth temperature
must be set at or below 60°C (140°F) with a bake time of 45 minutes or less. Temperatures in excess of
60°C (140°F) or bake durations longer than 45 minutes will require the HVTB be removed from the
vehicle prior to placing in the paint booth.
The vehicle is principally powered by an internal combustion engine, much like any ordinary vehicle.
However, it also transforms the energy that is normally wasted during stop and go operation (when coasting
and braking) into electricity, which is stored in the High Voltage Traction Battery (HVTB) until the moment it
is needed by the Electronically Controlled Continuously Variable Transmission (eCVT) traction motor or the
12-volt system. The traction motor is used to support the engine during acceleration and uphill drivn
low-speed driving situations, the vehicle may move under only battery power, without the internal combustion
engine running. The internal combustion engine may automatically shut off when the vehicle is stopped/idling
or when coasting under 75 km/h (47 mph) and will restart when the accelerator is depressed, when the traction
motor needs assistance, or if the HVTB state-of-charge is low. This avoids using excess fuel when the vehicle
is not in motion. The vehicle does not need to be plugged into an external source of electricity to be recharged.
The energy provided by the engine and the regenerative braking, via the eCVT traction motor and generator
motor, charges the HVTB .
The HVTB assembly, located behind the rear seat backrest, consists of the following components:
• HVTB
• HVTB service disconnect plug
• Battery Energy Control Module (BECM)
• High-voltage Bussed Electrical Center (BEC)
• HVTB connector and bracket (mounted to the high-voltage BEC )
• Battery Pack Sensor Module (BPSM)
• High-voltage low-current fuse (mounted in the high-voltage BEC )
• HVTB system wire harness
• HVTB cooling fan and jumper harness (accessed from the trunk area)
• HVTB cooling inlet duct
• HVTB cooling outlet duct (accessed from the trunk area)
• HVTB inlet air temperature sensor
• HVTB cooling inlet duct plate
• HVTB ground strap
• High-voltage BEC cover
All of the HVTB assembly components listed above can be individually serviced except the HVTB and the
HVTB system wire harness. The HVTB and HVTB system wire harness are serviced as part of the entire
HVTB assembly which includes all of the components in the list above except the HVTB cooling inlet duct
High-Voltage Traction Battery 5489

plate.
The high-voltage system also includes of the following components:
• High-voltage cable assembly

• eCVT , including motor generators and regenerative braking. For information on the eCVT , refer to
Section 307-01C and the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
• DC to DC Converter Control Module (DC/DC) located on the RH frame rail, behind the radiator
support. For information on the DC/DC , refer to Section 414-05 .
• Air Conditioning Compressor Module (ACCM) and A/C compressor assembly located on lower LH
side of the engine block. For information on the ACCM and A/C compressor assembly, refer to
Section 412-01 .


Workshop Manual
Special Tool(s)
Backprobe Pins
POM6411
Flex Probe Kit



The High Voltage Traction Battery (HVTB) consists of D-cell type batteries packaged into modules which
deliver approximately 275 volts DC to the high-voltage system. The HVTB provides cranking power to the
high-voltage generator motor inside the Electronically Controlled Continuously Variable Transmission
(eCVT). The HVTB also supplies electrical energy to the traction motor (also internal to the eCVT ) to propel
the vehicle when it is operating in electric mode only or to assist the gasoline engine (heavy acceleration).
When the engine is operating or the vehicle is moving, the high-voltage generator motor generates
high-voltage AC electricity. High-voltage AC generated by the generator motor can be used by the traction
motor or to re-charge the HVTB .
When the HVTB is being charged, high-voltage is converted from high-voltage AC to high-voltage DC
electrical power inside the eCVT and transmitted through the high-voltage cables to the HVTB .
The high-voltage DC electrical power is converted to low-voltage DC electrical power through the DC to DC
Converter Control Module (DC/DC). This low-voltage high-current DC electrical power is then supplied to
the 12-volt battery through the low-voltage battery cables.
The high-voltage system has a floating ground. The floating ground is designed to completely isolate the
high-voltage system from the vehicle chassis. The high-voltage cables are fully insulated (isolated) from all
vehicle components and circuits. There are no common connections (such as body grounds) used to conduct
the high-voltage power. The Battery Energy Control Module (BECM) monitors this system for any leakage of
current to the normal electrical system (similar to a household ground fault interrupter).
Battery Energy Control Module (BECM)
The BECM manages the condition of the HVTB to control its charging and discharging. The BECM also
manages the cooling of the HVTB by controlling a fan attached to the HVTB cooling outlet duct. The BECM
communicates with other vehicle modules on the High Speed Controller Area Network (HS-CAN) bus.

The BECM receives the following hard-wired inputs:
• HVTB interlock status

• Battery Pack Sensor Module (BPSM) information and status, via a dedicated (not accessible by a scan
tool) CAN between the BECM and BPSM
• Immediate shutdown request from the Transmission Control Module (TCM)
• Event notification status from the Restraints Control Module (RCM)
• Vehicle HS-CAN
• BPSM power, ground and control circuits
• HVTB cooling fan feedback
The BECM provides the following outputs:
• HVTB cooling fan Pulse Width Modulated (PWM) supply voltage

• Vehicle HS-CAN information
The BECM receives HS-CAN messages from the following modules:
• PCM
• TCM
• RCM
• DC/DC
The PCM HS-CAN messages received by the BECM include:
• Gas engine status (running or off)

• Contactor control request status
• Current vehicle mode (power up, engine wait, shutdown, etc.)
• Ready light request
• Battery estimated current
• Transaxle gear position
• R-Mode Rebalance enable request
• Engine speed
• Throttle plate position
• Ambient air inlet temperature
The TCM HS-CAN messages received by the BECM include:
• Vehicle speed, via the TCM

• TCM high-voltage input, via the TCM
The DC/DC HS-CAN messages received by the BECM include:
• DC/DC high-voltage input

• DC/DC high-voltage current
• DC/DC low-voltage input
• DC/DC over-temperature status
• DC/DC operation status
Battery Pack Sensor Module (BPSM)

The BPSM communicates with the BECM over a dedicated (not accessible by a scan tool) CAN bus. The
BPSM provides the current, voltage and temperature status of the HVTB to the BECM . This information is
needed by the BECM to control the HVTB and to determine the HVTB ability to receive and provide power
to the vehicle.
DC to DC Converter Control Module (DC/DC)
The DC/DC converter is a liquid-cooled component that converts high-voltage (179-343 volt) DC power to
low-voltage (12 volt) DC power. The converter provides power to the vehicle 12-volt battery and low-voltage
electrical systems. The PCM controls the operation of the DC/DC through an enable message from the PCM
to the DC/DC . For information on the DC/DC , refer to Section 414-05 .
Electronically Controlled Continuously Variable Transmission (eCVT)
The eCVT includes an internal generator motor and an internal traction motor. For information on the eCVT
and its operation, refer to Section 307-01C and the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
The eCVT generator motor generates high-voltage electricity for charging of the HVTB and/or providing
power to the traction motor. The generator motor is also used to start the gas engine. The generator motor is
an internal part of the eCVT and it cannot be repaired, only installed new as an assembly.
The eCVT traction motor is used to accelerate the vehicle from a stop when driving under electric power. The
traction motor is also used to recover energy during regenerative braking. The traction motor receives power
from the HVTB and/or from the eCVT generator motor. The traction motor is an internal part of the eCVT
and it cannot be repaired, only installed new as an assembly.
The regenerative braking system is designed to recapture some of the energy from braking and deceleration
events. It accomplishes this through the use of the traction motor and generator motor. This recaptured energy
is used to charge the HVTB . If the HVTB is adequately charged, the recaptured energy is used for gas engine
braking to slow the vehicle. The regenerative brake system is a series system. A series system is one in which
powertrain braking is used first, up to the limits of the powertrain torque capacity and battery capacity. After
optimum regeneration is used, the friction brakes are applied to supplement braking demands. For information
on regenerative braking, refer to Section 206-09 .
High-Voltage Bussed Electrical Center (BEC)
The high-voltage Bussed Electrical Center (BEC) acts as an interface between the high-voltage cables and the
HVTB . The high-voltage BEC houses the 3 contactors (precharge, positive and negative) which, when
commanded closed by the BECM , connect the HVTB to various components for high-voltage consumption
and/or charging of the HVTB . The high-voltage BEC design enables distribution of high-voltage to the
high-current side ( eCVT ) and low-current side ( DC/DC and Air Conditioning Compressor Module
(ACCM)). The low-current side is protected by a high-voltage/low-current 40A fuse. Any fault resulting in
excessive current on the low-current side will open the fuse, but will not affect operation of the high-current
side. The high-voltage BEC contains the contactors, the current sensor and the high-voltage/low-current 40
amp fuse.
The high-voltage BEC also interfaces with the BECM for monitoring of the high-voltage cable interlock
circuit and control of the contactors. The high-voltage BEC also houses the current sensor which is monitored
by the BPSM . The current sensor is used to help determine the load or rate of charge of the HVTB by sensing
current flow into or out of the HVTB .
High-Voltage Cable Assembly
All cables that carry high voltage are integrated into one high-voltage cable assembly that runs between the

DC/DC , the eCVT , the ACCM and the HVTB (via the high-voltage BEC ). Within the high-voltage cable
assembly are 4 basic circuits:
• The high-voltage/high-current cables between the HVTB and the eCVT .

• The high-voltage/low-current cables from the HVTB to the DC/DC and the ACCM .
• The interlock circuit consists of small-gauge wiring wrapped around the high-voltage cables. The
interlock circuit connectors are built in with the high-voltage cable connectors, and are either
disconnected simultaneously with the high-voltage cable or must be disconnected before
disconnecting the high-voltage cable, depending upon the type of connector being serviced.
• The LED and high-voltage AC wiring between the DC/AC inverter and AC power point. For
information on the DC/AC inverter system, refer to Section 414-05 .
High Voltage Traction Battery (HVTB)
The HVTB is a nominal 275 volts (actual operating range of 179-343 volts) DC energy source that receives
high-voltage electrical power when required from the eCVT . The HVTB also supplies high-voltage electrical
power when required to the eCVT , DC/DC and/or the ACCM .
The HVTB system is connected to a floating ground system that keeps it isolated from the vehicle's 12-volt
system. All charging and maintenance of the HVTB is managed by the BECM . Sensing of the HVTB (battery
state-of-charge, internal temperature, battery load) is done by the BPSM .
HVTB Service Disconnect Plug
The HVTB uses a service disconnect plug which connects directly to the HVTB . The service disconnect plug
has an internal circuit which includes a fuse. When the service disconnect plug is removed from the HVTB ,
high voltage is no longer supplied to the high-voltage BEC , although there is still high voltage available on 2
circuits monitored by the BPSM .
R-Mode Rebalance
Individual cells can deviate over the life of the HVTB . The purpose of the R-Mode Rebalance is to equalize
the individual cell charges. By rebalancing the cells the HVTB will maintain top efficiency. The rebalance
process charges the battery pack to near a full state of charge and keeps each individual cell charge within a
prescribed range of each other. The R-Mode Rebalance is sometimes run during vehicle operation as needed
and is controlled by the BECM . In some situations the BECM may not be able to properly adjust the cell
levels on its own and a DTC may be set. The DTC would direct the technician to perform a service R-Mode
Rebalance. This is done with the use of a scan tool by following the directions within the service function.
Vehicle Shut Down
A vehicle shut down signal is sent when the battery is about to open the contactors due to an internal fault or
has just opened the contactors due to an external input (external module commanding contactors to be opened
such as a crash event, interlock circuit failure, etc.). When vehicle shut down occurs, the Stop Safely warning
indicator will be illuminated warning that the vehicle will be shut down within a matter of seconds and that
the operator should pull off the road as soon as possible. Depending on the fault condition that lead to the shut
down, the vehicle may or may not re-start if the condition has corrected itself. If the fault condition is severe
enough, the fault will have to be repaired and DTCs cleared before the vehicle will re-start.

NOTE: Verify the service disconnect plug is properly inserted and locked into the lock position.
• High-voltage cables • Battery Junction Box (BJB) fuse(s):

• Electronically Controlled Continuously Variable ♦ 17 (10A)
Transmission (eCVT) ♦ 47 (10A)
• Air inlet grille and duct ♦ 48 (20A)
• Air outlet duct • Smart Junction Box (SJB) fuse 3
• High Voltage Traction Battery (HVTB) cooling fan (15A)
• Power sustain relay
• Circuitry
• Air inlet thermistor
• HVTB cooling fan
• DC to DC Converter Control
Module (DC/DC)
• eCVT
• HVTB
• High-voltage Bussed Electrical
Center (BEC)
• Service disconnect plug
• 12-volt battery

• refer to Section 418-00 , No Power To The Scan Tool, to diagnose no power to the VCM .



418-00 .
(CMDTCs).
8. Carry out the self-test diagnostics for the PCM and the BECM .
9. If the PCM DTCs retrieved are related to a driveability concern, refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual before proceeding to the next step.
10. If the BECM DTCs retrieved are related to the concern, go to the Battery Energy Control Module
(BECM) DTC Chart to continue diagnosis.
DTC Charts
Battery Energy Control Module (BECM) DTC Chart
NOTE: Network DTCs (U-codes) are often a result of intermittent concerns such as damaged wiring or low
battery voltage occurrences. Additionally, vehicle service procedures such as module reprogramming often set
network DTCs. Replacing a module to resolve a network DTC is unlikely to resolve the concern. To prevent
repeat network DTC concerns, inspect all network wiring, especially connectors. Test the vehicle battery
condition, refer to Section 414-01 .

B10A2:16 Crash Input: Circuit Voltage MEASURE voltage at Battery Energy Control Module (BECM)
Below Threshold C4237A-41, circuit CBB48 (GY/YE), harness side and
C4237A-42, circuit CBB48 (GY/YE), harness side. If less than 12
volts, INSPECT Battery Junction Box (BJB) fuse 48 (20A). If the
fuse is OK, REPAIR the circuit. If 12 volts is present, INSTALL a
new BECM . REFER to Battery Energy Control Module (BECM)
in this section. CLEAR the DTCs. REPEAT the self-test. TEST the
B11D5:68 Restraint Event Notification: NOTE: This DTC indicates the Restraints Control Module (RCM)
Vehicle Disabled: Event is outputting a fuel cutoff/crash event.
Information
RETRIEVE DTCs from the RCM and REFER to Section 501-20B
for further diagnosis.
B11D8:11 Restraint Event Notification: GO to Pinpoint Test AC .
Circuit Short To Ground

B11D8:15 Restraint Event Notification: GO to Pinpoint Test AD .

Circuit Short To Battery Or
Open
B11D8:31 Restraint Event Notification: With the ignition in the ON position, MEASURE frequency at
No Signal BECM C4237A-46, circuit CR167 (YE/VT) by back-probing the
connector.
If frequency is 9-11 Hz, INSTALL a new BECM . REFER to

Battery Energy Control Module (BECM) in this section.
If frequency is not 9-11 Hz, CHECK RCM and PCM for DTCs.
REFER to Section 501-20B or the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis.
CLEAR the DTCs. REPEAT the self-test. TEST the system for
normal operation.
If no DTCs are present, INSTALL a new RCM . REFER to

Section 501-20B .
Signal Frequency Too Low BECM C4237A-46, circuit CR167 (YE/VT) by back-probing the
connector.

normal operation.

Section 501-20B .
Signal Frequency Too High BECM C4237A-46, circuit CR167 (YE/VT) by back-probing the
connector.

normal operation.

Section 501-20B .
Signal Frequency Incorrect BECM C4237A-46, circuit CR167 (YE/VT) by back-probing the

connector.

normal operation.

Section 501-20B .
P0A0A:00 High Voltage System GO to Pinpoint Test A .
Interlock Circuit: No Sub
Type Information
P0A0C:00 High Voltage System GO to Pinpoint Test AQ .
Interlock Circuit Low: No
P0A7D:00 Hybrid Battery Pack State of GO to Pinpoint Test B .
a Charge Low: No Sub Type
Information
P0A7E:00 Hybrid Battery Pack Over If other BECM DTCs are present, address them first. If DTC
Temperature: No Sub Type P0A7E is the only DTC present, GO to Pinpoint Test C .
Information
a
P0A80:00 Replace Hybrid Battery NOTE: This DTC signals the High Voltage Traction Battery
Pack: No Sub Type (HVTB) is at the end of expected life. The customer may choose
Information not to install a new battery pack due to the cost of replacement. If a
new HVTB is not installed, the customer will experience reduced
fuel economy and reduced power, which will eventually lead to a
complete failure of the HVTB and the vehicle being unable to start.
INSTALL a new HVTB . REFER to High-Voltage Traction

Battery in this section.
normal operation.
P0A81:00 Hybrid Battery Pack Cooling If BECM DTC P0A82:00 is also present, diagnose that DTC first.
Fan 1 Control Circuit/Open: If DTC P0A81:00 is the only DTC present, GO to Pinpoint Test D
No Sub Type Information .
P0A82:00 Hybrid Battery Pack Cooling GO to Pinpoint Test E .
Fan 1 Performance/Stuck
Off: No Sub Type
Information
P0A8B:64 14 Volt Power Module GO to Pinpoint Test F .
System Voltage: Signal
Plausibility Failure
P0A9D:00 Hybrid Battery Temperature GO to Pinpoint Test G .
Sensor A Circuit Low: No
P0A9E:00 GO to Pinpoint Test G .

Hybrid Battery Temperature

Sensor A Circuit High: No
P0AA1:00 Hybrid Battery Positive GO to Pinpoint Test H .
a Contactor Circuit Stuck
Closed: No Sub Type
Information
P0AA2:00 Hybrid Battery Positive GO to Pinpoint Test H .
Contactor Circuit Stuck
Open: No Sub Type
Information
P0AA4:00 Hybrid Battery Negative GO to Pinpoint Test I .
a Contactor Circuit Stuck
Closed: No Sub Type
Information
P0AA5:00 Hybrid Battery Negative GO to Pinpoint Test I .
Contactor Circuit Stuck
Open: No Sub Type
Information
P0AA6:00 Hybrid Battery Voltage GO to Pinpoint Test J .
System Isolation Fault: No
P0AA7:00 Hybrid Battery Voltage CLEAR the DTCs and REPEAT the self-test. If the DTC is still
Isolation Sensor Circuit: No present. INSTALL a new Battery Pack Sensor Module (BPSM).
Sub Type Information REFER to Battery Pack Sensor Module (BPSM) in this section.
normal operation.
P0AA9:00 Hybrid Battery Voltage CLEAR the DTCs and REPEAT the self-test. If the DTC is still
Isolation Sensor Circuit present. INSTALL a new BPSM . REFER to Battery Pack Sensor
Low: No Sub Type Module (BPSM) in this section. CLEAR the DTCs. REPEAT the
Information self-test. TEST the system for normal operation.
P0AAA:00 Hybrid Battery Voltage CLEAR the DTCs and REPEAT the self-test. If the DTC is still
Isolation Sensor Circuit present, INSTALL a new BPSM . REFER to Battery Pack Sensor
High: No Sub Type Module (BPSM) in this section. CLEAR the DTCs. REPEAT the
Information self-test. TEST the system for normal operation.
P0AAE:00 Hybrid Battery Pack Air GO to Pinpoint Test K .
Temperature Sensor A
Circuit Low: No Sub Type
Information
P0AAF:00 Hybrid Battery Pack Air GO to Pinpoint Test K .
Temperature Sensor A
Circuit High: No Sub Type
Information
P0ABC:00 Hybrid Battery Pack Voltage GO to Pinpoint Test L .
Sense A Circuit Low: No
P0ABD:00 Hybrid Battery Pack Voltage GO to Pinpoint Test M .
Sense A Circuit High: No
P0AC0:00 Hybrid Battery Pack Current GO to Pinpoint Test T .
Sensor A Circuit

Range/Performance: No Sub
Type Information
Sensor A Circuit Low: No
Sensor A Circuit High: No
P0AC7:00 Hybrid Battery Temperature GO to Pinpoint Test N .
Sensor B Circuit Low: No
P0AC8:00 Hybrid Battery Temperature GO to Pinpoint Test N .
Sensor B Circuit High: No
P0ACC:00 Hybrid Battery Temperature GO to Pinpoint Test O .
Sensor C Circuit Low: No
P0ACD:00 Hybrid Battery Temperature GO to Pinpoint Test O .
Sensor C Circuit High: No
P0AD9:00 Hybrid Battery Positive GO to Pinpoint Test P .
Contactor Control
Circuit/Open GM: No Sub
Type Information
P0ADA:00 Hybrid Battery Positive GO to Pinpoint Test R .
Contactor Control Circuit
Type Information
P0ADC:00 Hybrid Battery Positive GO to Pinpoint Test U .
a Contactor Control Circuit
High: No Sub Type
Information
P0ADD:00 Hybrid Battery Negative GO to Pinpoint Test Q .
Contactor Control
Circuit/Open: No Sub Type
Information
P0ADE:00 Hybrid Battery Negative GO to Pinpoint Test R .
Contactor Control Circuit
Type Information
P0AE0:00 Hybrid Battery Negative GO to Pinpoint Test AH .
a Contactor Control Circuit
High: No Sub Type
Information
P0AE1:00 Hybrid Battery Precharge NOTE: This DTC is set by a no-start, caused when the contactor
a Contactor Circuit: No Sub precharge circuit fails and the HVTB contactors do not close. A
Type Information low 12-volt battery may also cause this DTC. The master vehicle
stop safely hazard (red triangle) warning indicator in the
Instrument Cluster (IC) will illuminate. This DTC is also set by a
fault in the DC to DC Converter Control Module (DC/DC) enable
circuit, the high-voltage bus, Electronically Controlled

Continuously Variable Transmission (eCVT) or the DC/AC

inverter and high-voltage wiring.
GO to Pinpoint Test AI .
P0AE5:00 Hybrid Battery Precharge GO to Pinpoint Test AJ .
a Contactor Circuit
Type Information
P0AE7:00 Hybrid Battery Precharge GO to Pinpoint Test AK .
a Contactor Circuit High: No
P0AEA:00 Hybrid Battery Temperature GO to Pinpoint Test S .
Sensor D Circuit Low: No
P0AEB:00 Hybrid Battery Temperature GO to Pinpoint Test S .
Sensor D Circuit High: No
P0AFB:00 Hybrid Battery System GO to Pinpoint Test V .
Voltage High: No Sub Type
Information
P0AFC:04 Hybrid Battery Pack Sensor CLEAR the DTCs and REPEAT the self-test. If DTC returns,
Module: System Internal INSTALL a new BPSM . REFER to Battery Pack Sensor Module
Failure (BPSM) in this section. CLEAR the DTCs. REPEAT the self-test.
P0AFC:49 Hybrid Battery Pack Sensor CLEAR the DTCs and REPEAT the self-test. If the DTC is still
Module: Internal Electronic present, INSTALL a new BPSM . REFER to Battery Pack Sensor
Failure Module (BPSM) in this section. CLEAR the DTCs. REPEAT the
P0AFC:4A Hybrid Battery Pack Sensor CLEAR the DTCs and REPEAT the self-test. If the DTC is still
Module: Incorrect present, INSTALL a new BPSM . REFER to Battery Pack Sensor
Component Installed Module (BPSM) in this section. CLEAR the DTCs. REPEAT the
P0AFC:67 Hybrid Battery Pack Sensor GO to Pinpoint Test AL .
Module: Signal Incorrect
After Event
P0AFD:00 Hybrid Battery Pack GO to Pinpoint Test W .
Temperature Too Low: No
P0B10:00 Hybrid Battery Pack Current GO to Pinpoint Test X .
Sensor B Circuit Low: No
P0B12:00 Hybrid Battery Pack Current GO to Pinpoint Test X .
Sensor B Circuit
Intermittent/Erratic: No Sub
Type Information
P0B1B:00 Hybrid Battery Pack Voltage GO to Pinpoint Test Y .
Sense C Circuit Low: No
P0B1C:00 Hybrid Battery Pack Voltage GO to Pinpoint Test AM .
Sense C Circuit High: No

P0B24:00 Hybrid Battery A Voltage NOTE: This DTC indicates the HVTB has cell modules with a
Unstable: No Sub Type voltage variation and should be replaced. The customer may
Information choose not to install a new battery pack due to the cost of
replacement. If a new HVTB is not installed, the customer will
experience reduced fuel economy and reduced power, which will
eventually lead to a complete failure of the HVTB and the vehicle
being unable to start.
INSTALL a new HVTB . REFER to High-Voltage Traction

P0B25:00 Hybrid Battery A Voltage NOTE: The customer may choose not to install a new battery pack
Low: No Sub Type due to the cost of replacement. If a new HVTB is not installed, the
Information customer will experience reduced fuel economy and reduced
power, which will eventually lead to a complete failure of the
HVTB and the vehicle being unable to start.
CHECK for other DTCs and diagnose any other DTCs first. If no
other DTCS are present, INSTALL a new HVTB . REFER to
High-Voltage Traction Battery in this section. CLEAR the DTCs.
REPEAT the self-test. TEST the system for normal operation.
P0B36:00 High Voltage Service GO to Pinpoint Test AN .
Disconnect Circuit High: No
P0B37:00 High Voltage Service GO to Pinpoint Test AO .
Disconnect Open: No Sub
Type Information
P0B3D:00 Hybrid Battery Voltage GO to Pinpoint Test AP .
Sense A Circuit Low: No
P0B3E:00 Hybrid Battery Voltage GO to Pinpoint Test AP .
Sense A Circuit High: No
P0B42:00 Hybrid Battery Voltage GO to Pinpoint Test AP .
Sense B Circuit Low: No
Sense B Circuit High: No
Sense C Circuit Low: No
Sense C Circuit High: No
P0B4C:00 Hybrid Battery Voltage GO to Pinpoint Test AP .
Sense D Circuit Low: No
Sense D Circuit High: No
P0B51:00 GO to Pinpoint Test AP .

Hybrid Battery Voltage

Sense E Circuit Low: No
Sense E Circuit High: No
Sense F Circuit Low: No
Sense F Circuit High: No
P0B5B:00 Hybrid Battery Voltage GO to Pinpoint Test AP .
Sense G Circuit Low: No
Sense G Circuit High: No
Sense H Circuit Low: No
Sense H Circuit High: No
Sense I Circuit Low: No Sub
Type Information
Sense I Circuit High: No
P0B6A:00 Hybrid Battery Voltage GO to Pinpoint Test AP .
Sense J Circuit Low: No Sub
Type Information
P0B6B:00 Hybrid Battery Voltage GO to Pinpoint Test AP .
Sense J Circuit High: No
P0B6F:00 Hybrid Battery Voltage GO to Pinpoint Test AP .
Sense K Circuit Low: No
Sense K Circuit High: No
Sense L Circuit Low: No
Sense L Circuit High: No
Sense M Circuit Low: No


P0B7A:00 Hybrid Battery Voltage GO to Pinpoint Test AP .
Sense M Circuit High: No
Sense N Circuit Low: No
P0B7F:00 Hybrid Battery Voltage GO to Pinpoint Test AP .
Sense N Circuit High: No
Sense O Circuit Low: No
Sense O Circuit High: No
Sense P Circuit Low: No
Sense P Circuit High: No
Sense Q Circuit Low: No
Sense Q Circuit High: No
Sense R Circuit Low: No
Sense R Circuit High: No
Sense S Circuit Low: No
Sense S Circuit High: No
Sense T Circuit Low: No
Sense T Circuit High: No
P0BA1:00 Hybrid Battery Voltage GO to Pinpoint Test AP .
Sense U Circuit Low: No
P0BA2:00 GO to Pinpoint Test AP .

Hybrid Battery Voltage

Sense U Circuit High: No
Sense V Circuit Low: No
Sense V Circuit High: No
P0BAB:00 Hybrid Battery Voltage GO to Pinpoint Test AP .
Sense W Circuit Low: No
P0BAC:00 Hybrid Battery Voltage GO to Pinpoint Test AP .
Sense W Circuit High: No
P0BB0:00 Hybrid Battery Voltage GO to Pinpoint Test AP .
Sense X Circuit Low: No
Sense X Circuit High: No
Sense Y Circuit Low: No
Sense Y Circuit High: No
P0BBA:00 Hybrid Battery Voltage GO to Pinpoint Test AP .
Sense Z Circuit Low: No
P0BBB:00 Hybrid Battery Voltage GO to Pinpoint Test AP .
Sense Z Circuit High: No
P0BC4:00 Hybrid Battery Temperature GO to Pinpoint Test Z .
Sensor E Circuit Low
P0BC5:00 Hybrid Battery Temperature GO to Pinpoint Test Z .
Sensor E Circuit High
P1A0A:11 Immediate Shutdown Signal GO to Pinpoint Test AA .
A: Circuit Short To Ground
a A: Circuit Short To Battery
A: Circuit Short To Battery
Or Open
P1A15:11 Immediate Shutdown Signal GO to Pinpoint Test AB .
B: Circuit Short To Ground
P1A15:12 a Immediate Shutdown Signal GO to Pinpoint Test AB .
B: Circuit Short To Battery
P1A15:15 Immediate Shutdown Signal GO to Pinpoint Test AB .
B: Circuit Short To Battery

Or Open
U0074:00 Control Module GO to Pinpoint Test AE .
Communication Bus "B"
Off: No Sub Type
Information
U0100:00 Lost Communication With NOTE: DTC U0100:00 indicates lost communication with the
ECM/PCM "A": No Sub PCM.
Type Information
REFER to Section 418-00 to diagnose the lost communication with
the PCM.
U0101:00 Lost Communication with NOTE: DTC U0101:00 indicates lost communication with the
Transmission Control TCM .
Module (TCM): No Sub
Type Information REFER to Section 418-00 to diagnose the lost communication with
the TCM .
U0151:00 Lost Communication NOTE: DTC U0151:00 indicates lost communication with the
Restraints Control Module: RCM .
REFER to Section 418-00 to diagnose the lost communication with
the RCM .
U0155:00 Lost Communication NOTE: DTC U0155:00 indicates lost communication with the IPC
Instrument Panel Cluster module.
(IPC) Control Module: No
Sub Type Information REFER to Section 418-00 to diagnose the lost communication with
the IPC module.
U0298:00 Lost Communication to DC NOTE: DTC U0298:00 indicates lost communication with the
to DC Converter Control DC/DC .
Module "A": No Sub Type
Information REFER to Section 418-00 to diagnose the lost communication with
the DC/DC .
U029A:00 Lost Communication with NOTE: DTC U029A:00 indicates lost communication with the
Hybrid Battery Pack Sensor BPSM .
Module: No Sub Type
Information Diagnose any other BECM DTCs first. If no other BECM DTCs
are present, check the dedicated CAN circuits BECM C4237B-2,
circuit J1-A02, harness side and BPSM C4238B-23, circuit
J1-A02, harness side; and between BECM C4237B-18, circuit
J1-A18, harness side and BPSM C4238B-22, circuit J1-A18,
harness side for faults. If OK, INSTALL a new BPSM . REFER to
Battery Pack Sensor Module (BPSM) in the section. CLEAR the
DTCs. REPEAT the self-test. TEST the system for normal
operation.
U0300:05 Internal Control Module CONFIGURE the BECM . REFER to Section 418-01 to CARRY
Software Incompatibility: OUT Programmable Module Installation (PMI). If the concern is
System Programming still present, INSTALL a new BECM . REFER to Battery Energy
Failure Control Module (BECM) in this section. CLEAR the DTCs.
U0335:00 Software Incompatibility CONFIGURE the BECM and BPSM . REFER to Section 418-01
with Hybrid Battery Pack to CARRY OUT Programmable Module Installation (PMI).
Sensor Module: No Sub CLEAR the DTCs. REPEAT the self-test. If the concern is still
Type Information present, INSTALL a new BECM . REFER to Battery Energy
Control Module (BECM) in this section. CLEAR the DTCs.

REPEAT the self-test. If the concern is still present, INSTALL a

new BPSM . REFER to Battery Pack Sensor Module (BPSM) in
this section. CLEAR the DTCs. REPEAT the self-test. TEST the
U0336:00 Software Incompatibility NOTE: DTC U0336:00 indicates the BECM received an
with Restraints Control undetermined value from the RCM fuel pump cutoff request
Module: No Sub Type message.
Information
RETRIEVE RCM DTCs. REFER to Section 501-20B for further
diagnosis of the RCM .
a
U0401:66 Invalid Data Received From CARRY OUT PCM self-test. REFER to the Powertrain
ECM/PCM A: Signal Has Control/Emissions Diagnosis (PC/ED) manual for further
Too Many diagnosis of the PCM DTCs.
Transitions/Events
U0401:68 Invalid Data Received From NOTE: DTC U0401:68 indicates a High Speed Controller Area
ECM/PCM A: Event Network (HS-CAN) message from the PCM is outside normal
Information limits due to a faulty PCM input.
RETRIEVE the PCM DTCs related to engine speed or ambient air

temperature. REFER to Powertrain Control/Emissions Diagnosis
(PC/ED) manual for further diagnosis of the PCM DTCs.
U0402:68 Invalid Data Received From NOTE: DTC U0402:68 indicates a HS-CAN message from the
TCM : Event Information TCM is outside normal limits due to a faulty TCM input.
RETRIEVE TCM DTCs related to vehicle speed or high-voltage

input. REFER to Powertrain Control/Emissions Diagnosis
(PC/ED) manual for further diagnosis of the TCM .
U0424:68 Invalid Data Received From NOTE: DTC U0424:68 indicates a HS-CAN message from the IC
HVAC Control Module: module (gateway message, originates from HVAC control module
Event Information on Medium Speed Controller Area Network (MS-CAN) is outside
normal limits due to a faulty HVAC control module input.
RETRIEVE HVAC control module DTCs related to recirculation

door, airflow or blower motor operation. REFER to Section
412-00B for further diagnosis of the HVAC control module.
Restraints Control Module: RCM is outside normal limits.
The BECM received an invalid fuel pump cutoff request message.
RETRIEVE RCM DTCs. REFER to Section 501-20B for further
diagnosis of the RCM .
DC to DC Converter Control DC/DC is outside normal limits.
Module "A": Event
Information The BECM received an invalid low-voltage or high-voltage
message. RETRIEVE DC/DC DTCs. REFER to Section 414-05
for further diagnosis of the DC/DC .
U1003:49 System Clock: Internal CLEAR DTCs and REPEAT self test. If the DTC is still present,
Electronic Failure INSTALL a new BECM . REFER to Battery Energy Control
Module (BECM) in this section. CLEAR the DTCs. REPEAT the
U1006:00 GO to Pinpoint Test AE .

Sub Network Controller

Area Network (CAN)
Initialization Failure: No
U200D:12 Control Module Output MEASURE voltage at the BECM C4237B-51, circuit J1-A51,
Power A: Circuit Short To harness side with ignition in the OFF position. If no voltage is
Battery present, INSTALL a new BPSM . REFER to Battery Pack Sensor
Module (BPSM) in this section.
If voltage is present, INSTALL a new HVTB (includes HVTB

system wire harness). REFER to High-Voltage Traction Battery in
this section.
normal operation.
U200D:13 Control Module Output MEASURE voltage at the BECM C4237B-51, circuit J1-A51,
Power A: Circuit Open harness side with ignition in the ON position. If voltage is less than
10 volts, REPAIR the circuit. If voltage is greater than 10 volts,
INSTALL a new BPSM . REFER to Battery Pack Sensor Module
(BPSM) in this section. CLEAR the DTCs. REPEAT the self-test.
U3000:04 Control Module: System CLEAR DTCs and VERIFY the 12-volt battery is in good
Internal Failure condition and fully charged. Let vehicle sit a minimum of 7 hours
without an ignition cycle. REPEAT the self-test.
If DTC returns, INSTALL a new BECM . REFER to Battery

Energy Control Module (BECM) in this section. CLEAR the
operation.
If DTC does not return, return the vehicle to the customer. Concern
is not present at this time.
U3000:41 a Control Module: General CLEAR the DTCs. REPEAT the self-test.
Checksum Failure
If DTC returns, INSTALL a new BECM . REFER to Battery
Energy Control Module (BECM) in this section. CLEAR the
operation.
U3000:46 Control Module: CLEAR the DTCs. REPEAT the self-test.
Calibration/Parameter
Memory Failure If DTC returns, INSTALL a new BECM and run R-Mode
Rebalance using a scan tool. REFER to Battery Energy Control
Module (BECM) in this section. CLEAR the DTCs. REPEAT the
U3001:00 a Control Module Improper GO to Pinpoint Test AF .
Shutdown: No Sub Type
Information

U3003:16 Battery Voltage: Circuit GO to Pinpoint Test AF .

U3003:17 Battery Voltage: Circuit GO to Pinpoint Test AF .
U3003:62 Battery Voltage: Signal GO to Pinpoint Test AG .
Compare Failure
a Reports as a continuous memory (historical) DTC only.
Transmission Control Module (TCM) DTC Chart

P0A0A:00 High Voltage System Interlock GO to Pinpoint Test A .
Circuit: No Sub Type
Information
All other - REFER to the Transmission Control Module (TCM) DTC
DTCs chart in the Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
Symptom Chart
Symptom Chart
• The High Voltage Traction Battery (HVTB) is noisy

• Obstructions
• With the ignition in the ON position and the engine ON or OFF, listen in the HVTB area for unusl or
excessive noise. COMPARE the noise to a similar vehicle. If noise from the fan is excessive,
INSPECT the inlet and outlet air ducts for obstructions. If no obstructions are found and the fan is still
noisy, INSTALL a new fan. REFER to High-Voltage Traction Battery Cooling Fan in this section.

• The low-voltage battery is discharged or voltage is low
• 12-volt battery
• DC/DC
• 12-volt battery cables
• REFER to Section 414-05 to diagnose the DC to DC Converter Control Module (DC/DC).
Pinpoint Tests
Pinpoint Test A: DTC P0A0A:00
Normal Operation
The Battery Energy Control Module (BECM) checks for continuity of the high-voltage system interlock
circuit. The interlock circuit must have continuity before high-voltage will be supplied to the vehicle. The
interlock circuit voltage travels through each of the high-voltage components and high-voltage cables and
back to the BECM . This fault will illuminate the stop safely hazard (red triangle) warning indicator and shut
down the vehicle.
• DTC P0A0A:00 (High Voltage System Interlock Circuit: No Sub Type Information) - Fault sets when
the BECM does not sense interlock circuit continuity. This indicates the interlock circuit is open.

• BECM
• DC to DC Converter ControModule (DC/DC)
• Transmission Control Module (TCM) (part of Electronically Controlled Continuously Variable
Transmission (eCVT))
• High-voltage cables
PINPOINT TEST A: DTC P0A0A:00
NOTICE: Use the correct probe adapter(s) from the Flex Probe Kit when taking measurements. Failure
to use the correct probe adapter(s) may damage the connector.

A1 CHECK BECM PID HIGH VOLTAGE INTERLOCK INPUT

STATUS (VOLTINTINP)
Yes
• Ignition ON. Concern is not present at this
• Connect the scan tool. time and may be intermittent.
• Enter the following diagnostic mode on the scan tool: INSPECT all high-voltage
DataLogger - BECM . connections. CLEAR the
• Monitor the BECM PID VOLTINTINP. DTCs. REPEAT the self-test.
• Does the PID VOLTINTINP read closed? TEST the system for normal
operation.
No
GO to A2 .
A2 MEASURE RESISTANCE OF INTERLOCK CIRCUIT
Yes
• Ignition OFF. INSTALL a new BECM .
• Disconnect: BECM C4237B. REFER to Battery Energy
• Measure the resistance between BECM C4237B-44, circuit Control Module (BECM) in
J1-A44 harness side and BECM C4237B-47, circuit J1-A47 this section. CLEAR the DTCs.
harness side. REPEAT the self-test. TEST
operation.
No
GO to A3 .
• Repeat the measurement between BECM C4237B-44, circuit

J1-A44 harness side and BECM C4237B-47, circuit J1-A47
harness side while wiggling the connectors and flexing the wire
harness, where accessible.
A3 CHECK INTERLOCK CIRCUIT TO TCM
Yes
WARNING: Never install the service disconnect plug GO to A4 .
when a high-voltage service cover is removed. Always install
the cover prior to connecting the service disconnect plug. No
The cover prevents inadvertent contact with the high voltage INSTALL new high-voltage
which is present at several points under the cover. Failure to cables. REFER to
follow these instructions may result in serious personal High-Voltage Cables in this
injury or death. section. CLEAR the DTCs.
• Ignition OFF. the system for normal
• Depower the High Voltage Traction Battery (HVTB) system. operation.
Refer to High-Voltage Traction Battery Systems Depowering in
this section.
• Disconnect the 12-volt battery. Refer to Section 414-01 .
• Disconnect: High-voltage Bussed Electrical Center (BEC)
C4236B.
• Disconnect: TCM C1458C.
PINPOINT TEST A: DTC P0A0A:00 5511

• Measure the resistance between high-voltage BEC C4236B,

harness side and TCM C1458C, harness side as follows:
BEC C4236B Circuit TCM C1458C

C4236B-1 CYB04 (VT/BN) C1458C-1
C4236B-2 CYB03 (BN/YE) C1458C-2
• Repeat the measurement between BEC C4236B, harness side

and TCM C1458C, harness side while wiggling the connectors
and flexing the wire harness, where accessible.
A4 CHECK INTERLOCK CIRCUIT TO ACCM AND DC/DC
Yes
• Disconnect: BEC C4236A. GO to A5 .
• Disconnect: ACCM C1469B.
• Disconnect: DC/DC C1457A. No
• Measure the resistance between high-voltage BEC C4236A, INSTALL new high-voltage
harness side, ACCM C1469B, harness side and DC/DC cables. REFER to
C1457A, harness side as follows: High-Voltage Cables in this
section. CLEAR the DTCs.
operation.
BEC C4236A Circuit DC/DC C1457A
C4236A-3 CYD02 (WH/BN) C1457A-3
BEC C4236A Circuit ACCM C1469B

C4236A-4 CYB03 (BN/YE) C1469B-4
ACCM C1469B Circuit DC/DC C1457A

C1469B-3 CYD01 (BN/WH) C1457A-4

• Repeat the measurements between BEC C4236A, harness side,

ACCM C1469B, and DC/DC C1457A, harness side while
wiggling the connectors and flexing the wire harness, where
accessible.
A5 CHECK DC/DC INTERLOCK RESISTANCE
Yes
• Measure the resistance between DC/DC C1457A pin 3 and pin GO to A6 .
4, component side.
No
INSTALL a new DC/DC .
CLEAR the DTCs. REPEAT
the self-test. TEST the system

A6 CHECK ACCM INTERLOCK RESISTANCE
Yes
• Measure the resistance between ACCM C1469B, pin 3 and pin GO to A7 .
4, component side.
No
INSTALL a new ACCM and
A/C compressor assembly.

A7 CHECK TCM INTERLOCK RESISTANCE
Yes
• Measure the resistance between TCM C1458C, pin 1 and pin 2, GO to A8 .
component side.
No
INSTALL a eCVT . REFER to
Section 307-01C . CLEAR the
operation.


A8 CHECK THE HIGH-VOLTAGE CABLES USING BECM
PID HIGH VOLTAGE INTERLOCK INPUT STATUS
(VOLTINTINP)
Yes
• Install new high-voltage cables. Refer to High-Voltage Cables Repair is complete. CLEAR
in this section. the DTCs. REPEAT the
• Connect the 12-volt battery. Refer to Section 414-01 . self-test. TEST the system for
• Connect: Service Disconnect Plug. normal operation.
• Ignition ON.
DataLogger - BECM . GO to A9 .
• Monitor the BECM PID VOLTINTINP.
• Does the PID VOLTINTINP read closed?
A9 CHECK THE DC/DC USING BECM PID HIGH VOLTAGE
INTERLOCK INPUT STATUS (VOLTINTINP)
Yes
WARNING: Never install the service disconnect plug Repair is complete. CLEAR
when a high-voltage service cover is removed. Always install the DTCs. REPEAT the
the cover prior to connecting the service disconnect plug. self-test. TEST the systefor
The cover prevents inadvertent contact with the high voltage normal operation.
which is present at several points under the cover. Failure to
follow these instructions may result in serious personal No
injury or death. GO to A10 .
• Ignition OFF.
• Depower the HVTB system. Refer to High-Voltage Traction
Battery Systems Depowering in this section.
• Install a new DC/DC . Refer to Section 414-05 .
• Connect the 12-volt battery. Refer to Section 414-01 .
• Connect: Service Disconnect Plug.
• Ignition ON.
DataLogger - BECM .
A10 CHECK THE ACCM USING BECM PID HIGH VOLTAGE
Yes
the cover prior to connecting the service disconnect plug. self-test. TEST the system for

injury or death. GO to A11 .
• Ignition OFF.
• Install a new ACCM . Refer to Section 412-01 .
• Ignition ON.
DataLogger - BECM .
• Does the PID VOLTINTINP readlosed?
A11 CHECK THE HVTB USING BECM PID HIGH VOLTAGE
Yes
the cover prior to connecting the service disconnect plug. self-test. TEST the system for
injury or death. INSTALL a new eCVT .
REFER to Section 307-01C .
• Ignition OFF. CLEAR the DTCs. REPEAT
• Depower the HVTB system. Refer to High-Voltage Traction the self-test. TEST the system
Battery Systems Depowering in this section. for normal operation.
• Install a new HVTB (includes HVTB system wire harness).
Refer to High-Voltage Traction Battery in this section.
• Ignition ON.
DataLogger - BECM .
Pinpoint Test B: DTC P0A7D:00
Normal Operation
The Battery Energy Control Module (BECM) monitors the High Voltage Traction Battery (HVTB)
state-of-charge. When voltage drops to a low level, the vehicle will shut down and/or will not start/re-start
until the voltage level has been increased to a nominal level. This condition may occur if the vehicle has been
stored for an extended period of time. The stop safely hazard (red triangle) warning indicator will illuminate
and the vehicle will shut down and not re-start.

• P0A7D:00 (Hybrid Battery Pack State Of Charge Low: No Sub Type Information) - Fault sets when
the ignition switch is first turned to the ON position, or when the ignition switch is in the START
position and battery pack voltage falls below a threshold. Reports as a continous memory (historical)
DTC only.

• HVTB
PINPOINT TEST B: DTC P0A7D:00

B1 RETRIEVE ALL BECM DTCs
Yes
• Connect the scan tool. REFER to the Battery Energy Control
• Ignition ON. Module (BECM) DTC Chart and
• Enter the following diagnostic mode on the scan tool: diagnose all other DTCs first.
Self Test - BECM .
• Do any DTCs other than P0A7D:00 exist? No
GO to B2 .
B2 MONITOR BECM PIDs HYBRID BATTERY
MINIMUM BATTERY MODULE VOLTAGE
(HEVMINVOLT) AND HYBRID BATTERY PACK
VOLTAGE (BATPACKVOLT)
Yes
• Enter the following diagnostic mode on the scan tool: Concern not present at this time.
DataLogger - BECM . CLEAR the DTCs. REPEAT the
• Monitor BECM PIDs HEVMINVOLT and self-test. TEST the system for normal
BATPACKVOLT. operation.
• Is HEVMINVOLT above 4.8 volts and/or
BATPACKVOLT above 158 volts? No
INSTALL a new HVTB (includes
HVTB system wire harness). REFER to
High-Voltage Traction Battery in this
section.

operation.
Pinpoint Test C: DTC P0A7E:00
Normal Operation
With the ignition in the ON position and the engine running or OFF, the Battery Energy Control Module
(BECM) monitors and maintains the High Voltage Traction Battery (HVTB) temperature within a specific
range. The HVTB has an external fan that circulates air within the HVTB so a specific temperature range is
maintained. A thermistor is mounted to the inlet air duct which monitors inlet air temperature along with 5
thermistors inside the HVTB which all monitor HVTB temperature. The ideal HVTB temperature is 25°C
PINPOINT TEST B: DTC P0A7D:00 5516

(77°F) with a desired range of 20°C (68°F) to 30°C (86°F). The BECM will shut the vehicle down and the
powertrain malfunction (wrench) warning indicator will illuminate when the fault condition is present.
• DTC P0A7E:00 (Hybrid Battery Pack Over Temperature: No Sub Type Information) - Fault sets if
the HVTB temperature exceeds 60°C (140°F).

• HVTB fan
• HVTB inlet air duct
• BECM
PINPOINT TEST C: DTC P0A7E:00

C1 CHECK BECM DTCs
Yes
• Connect the scan tool. For DTC P0A81:00, GO to Pinpoint Test D .
• Ignition ON.
• Enter the following diagnostic mode on the For DTC P0A82:00, GO to Pinpoint Test E .
scan tool: Self Test - BECM .
• Is DTC P0A81:00 or P0A82:00 No
retrieved? GO to C2 .
C2 VERIFY THE HVTB FAN IS
OPERATIONAL
Yes
• Carry out the self-test of the BECM while GO to C3 .
noting the HVTB cooling fan operation.
• Did the HVTB cooling fan operate No
during self-test? GO to Pinpoint Test D .
C3 VERIFY THE VEHICLE INLET AND
OUTLET AIR DUCTS ARE CLEAR
Yes
• Open the trunk and fold down the rear seat
back to gain access to the HVTB . No
• Check the outlet air duct in the trunk on the REMOVE the debris or obstruction from air inlet or
side of the battery and air inlet duct at the outlet duct. CLEAR the DTCs. REPEAT the
bottom of the battery in the passenger self-test. TEST the system for normal operation.
compartment for any debris or obstruction.
• Are the inlet and outlet air ducts free of
debris or obstructions?
C4 CHECK THE HVTB FAN OPERATION
Yes
• Start the engine. GO to C5 .
scan tool: DataLogger - BECM . No
• Monitor the BECM PIDs Fan Speed INSTALL a new HVTB cooling fan. REFER to
Demanded (FAN_DEM) and Fan Speed High-Voltage Traction Battery Cooling Fan in this
Indicated (FAN_IND). section. CLEAR the DTCs. REPEAT the self-test.
• Using the output state control FAN_DEM, TEST the system for normal operation.

set the fan speed to 3,000 rpm.

• Monitor the PID FAN_IND.
• Does the PID FAN_IND read between
2,400 and 3,150?
C5 CHECK BECM PID HYBRID BATTERY
TEMPERATURE (BATT_TEMP)
Yes
• Drive the vehicle while monitoring the GO to C6 .
BECM PIDs FAN_IND and
BATT_TEMP. No
• When PID BATT_TEMP reaches 35°C INSTALL a new BECM . REFER to Battery Energy
(95°F) monitor PID FAN_IND. Control Module (BECM) in this section. CLEAR
• Does PID FAN_IND read at least 1,500 the DTCs. REPEAT the self-test. TEST the system
rpm? for normal operation.
C6 CHECK FOR CORRECT BECM
OPERATION
Yes
• Ignition OFF. INSTALL a new BECM . REFER to Battery Energy
• Check the BECM harness and component Control Module (BECM) in this section. TEST the
side connectors for: system for normal operation.
♦ corrosion.
• Connect the BECM and make sure the The system is operating correctly at this time. The
connectors seat correctly. concern may have been caused by a loose or
concern is still present. the self-test. TEST the system for normal operation.
Pinpoint Test D: DTC P0A81:00
Normal Operation
With the ignition in the ON position and the engine running or OFF (the engine must have started at least
once after the ignition was cycled to ON), the external fan for the High Voltage Traction Battery (HVTB)
circulates air to maintain a specific temperature range. The fan operation is controlled by the Battery Energy
Control Module (BECM) based upon information received from thermistors located inside the HVTB . The
stop safely hazard (red triangle) warning indicator or powertrain malfunction (wrench) warning indicator will
illuminate when a fault condition is present.
• P0A81:00 (Hybrid Battery Pack Cooling Fan 1 Control Circuit Open: No Sub Type Information) -
Fault sets if the BECM fan control output circuit indicates a fault for 5 seconds or more.

• BECM
• Cooling fan
• HVTB
PINPOINT TEST C: DTC P0A7E:00 5518

PINPOINT TEST D: DTC P0A81:00

D1 RETRIEVE ALL BECM DTCs
Yes
• Connect the scan tool.
• Ignition ON. No
• Enter the following diagnostic mode INSPECT inline C4013 and HVTB cooling fan C4232
on the scan tool: Clear DTCs - BECM for pushed-out or corroded pins and REPAIR as
. necessary. WIGGLE the wiring harness. REPEAT the
• Enter the following diagnostic mode self-test.
on the scan tool: lf-Test - BECM .
• Is DTC P0A81:00 or P0A82:00 If DTC P0A81:00 or DTC P0A82:00 is retrieved, GO to
present? D2 .
If no DTCs are retrieved, The concern may have been

caused by pushed-out or corroded pins. RETURN the
vehicle to the customer.
D2 CHECK FOR A SHORT TO
GROUND IN THE FAN CONTROL
CIRCUIT
Yes
• Disconnect: HVTB Cooling Fan
C4232. No
• Disconnect: BECM C4237A. REPAIR the circuit. CLEAR the DTCs. REPEAT the
• Measure the resistance between self-test. TEST the system for normal operation.
BECM C4237A-14, circuit VYB18
(WH/GN), harness side and ground.

ohms?
D3 CHECK HVTB COOLING FAN
GROUND CIRCUIT
Yes
• Connect: BECM C4237A. INSTALL a new fan. REFER to High-Voltage Traction
• Ignition ON. Battery Cooling Fan in this section. CLEAR the DTCs.
• Enter the following diagnostic mode REPEAT the self-test. TEST the system for normal
on the scan tool: Self Test - BECM operation.
(fan still disconnected).
PINPOINT TEST D: DTC P0A81:00 5519

• Is DTC P0A82:00 present? No

GO to D4 .
D4 CHECK FOR CORRECT BECM
OPERATION
Yes
• Check the BECM harness and Control Module (BECM) in this section. TEST the
component side connectors for: system for normal operation.
♦ corrosion.
• Connect the BECM and make sure the The system is operating correctly at this time. The
connectors seat correctly. concern may have been caused by a loose or corroded
• Operate the system and determine if connector. CLEAR the DTCs. REPEAT the self-test.
the concern is still present. TEST the system for normal operation.
Pinpoint Test E: DTC P0A82:00
Normal Operation
once after the ignition was cycled to ON), the external fan for the High Voltage Traction Battery (HVTB)
circulates air to maintain a specific temperature range. The fan operation is controlled by the Battery Energy
Control Module (BECM) based upon information received from thermistors located inside the HVTB . The
BECM monitors the frequency returned to the BECM from the fan to determine actual fan speed. This signal
may be incorrect if the fan or wiring are at fault. Powertrain malfunction (wrench) warning indicator will
illuminate.
• P0A82:00 (Hybrid Battery Pack Cooling Fan 1 Performance/Stuck Off: No Sub Type Information) -
Fault sets when cooling fan speed does not match what was commanded by the BECM for 8 seconds.

• Fuse
• BECM
PINPOINT TEST E: DTC P0A82:00

E1 RETRIEVE ALL BECM DTCs
Yes

• Ignition ON. No
• Enter the following diagnostic mode on the INSPECT inline C4013 and HVTB cooling fan
scan tool: Clear DTCs - BECM . C4232 for pushed-out or corroded pins and
• Enter the following diagnostic mode on the REPAIR as necessary. WIGGLE the wiring
scan tool: Self-Test - BECM . harness. REPEAT the self-test.
• Is DTC P0A81:00 or P0A82:00 present?
If DTC P0A81:00 or DTC P0A82:00 is
retrieved, GO to E2 .
If no DTCs are retrieved, The concern may have

been caused by pushed-out or corroded pins.
RETURN the vehicle to the customer.
E2 VERIFY THE VEHICLE INLET AND
OUTLET AIR DUCTS ARE CLEAR
Yes
• Open the trunk and fold down the rear seat
back to gain access to the HVTB . No
• Check the outlet air duct in the trunk on the REMOVE the debris or obstruction from air inlet
side of the battery and air inlet duct at the or outlet duct. CLEAR the DTCs. REPEAT the
bottom of the battery in the passenger self-test. TEST the system for normal operation.
compartment for any debris or obstruction.
• Are the inlet and outlet air ducts free of
debris or obstructions?
E3 CHECK HVTB COOLING FAN SPEED
Yes
• Connect the scan tool. END output state control. GO to E8 .
scan tool: DataLogger - BECM . No
• Ignition in the ON position. END output state control. GO to E4 .
• Using the output state control PID Fan Speed
Demanded (FAN_DEM), set the HVTB
cooling fan speed to approximately 3,000 rpm.
• Monitor the PID Fan Speed Indicated
(FAN_IND).
• Does the PID FAN_IND read between 2,700
and 3,300?
E4 CHECK HVTB COOLING FAN GROUND
CIRCUIT
Yes
• Disconnect: HVTB Cooling Fan C4232.
• Measure the resistance between HVTB No
cooling fan C4232-4, circuit GD128 (BK/GN), REPAIR high resistance or an open in the circuit.
harness side and ground. CLEAR the DTCs. REPEAT the self-test. TEST
PINPOINT TEST E: DTC P0A82:00 5521


E5 CHECK HVTB COOLING FAN POWER
CIRCUIT
Yes
• Measure the voltage between HVTB cooling
fan C4232-1, circuit SBP03 (BU/RD), harness No
side and ground. VERIFY the Smart Junction Box (SJB) fuse 3
(15A) is OK. If the fuse is OK, REPAIR the
circuit. If not OK, REFER to the Wiring
Diagrams manual to identify the possible causes
of the circuit short. CLEAR the DTCs. REPEAT
operation.

E6 CHECK FOR AN OPEN FAN CONTROL
CIRCUIT
Yes
• Disconnect: BECM C4237A.
• Measure the resistance between BECM No
C4237A-14, circuit VYB18 (WH/GN), REPAIR high resistance or an open in the circuit.
harness side and HVTB cooling fan C4232-2, CLEAR the DTCs. REPEAT the self-test. TEST
circuit VYB18 (WH/GN), harness side . the system for normal operation.

E7 CHECK FOR AN OPEN OR A SHORT TO
GROUND IN THE FAN FEEDBACK CIRCUIT
Yes
• Measure the resistance between GO to E8 .
(GY/VT), harness side and HVTB No
cooling fan C4232-3, circuit VYB19 REPAIR the circuit. CLEAR the DTCs.
(GY/VT), harness side. REPEAT the self-test. TEST the system for

• Measure the resistance between normal operation.

(GY/VT), harness side and ground.
• Is the resistance of the circuit less than 5

ohms and greater than 10,000 ohms to
ground?
E8 MEASURE SIGNAL FROM BECM FOR
FAN CONTROL CIRCUIT
Yes
• Connect: BECM C4237A (leave fan GO to E9 .
disconnected).
• Ignition ON. No
• Using the output state control PID Fan Speed GO to E11 .
Demanded (FAN_DEM), set the HVTB
cooling fan speed to approximately 3,000 rpm.
• Measure the frequency by back-probing
between BECM C4237A-14, circuit VYB18
(WH/GN), harness side and ground.
• Is the frequency approximately 90-110 Hz?

E9 MEASURE SIGNAL FROM BECM FOR
FAN FEEDBACK CIRCUIT
Yes
• With the ignition still in the ON position and GO to E11 .
the HVTB cooling fan still commanded to
3,000 rpm, measure the frequency by No
back-probing between BECM C4237A-12, GO to E10 .
circuit VYB19 (GY/VT), harness side and
ground.

• Is the frequency approximately 205-245

Hz?
E10 MEASURE VOLTAGE FROM BECM FOR
FAN FEEDBACK CIRCUIT
Yes
• With the ignition still in the ON position and GO to E11 .
the HVTB cooling fan still commanded to
3,000 rpm, measure the voltage by No
back-probing between BECM C4237A-12, INSTALL a new HVTB cooling fan. REFER to
circuit VYB19 (GY/VT), harness side and High-Voltage Traction Battery Cooling Fan in
ground. this section. CLEAR the DTCs. REPEAT the
• Is the voltage approximately 3 to 7 volts?

E11 CHECK FOR CORRECT BECM
OPERATION
Yes
• Check the BECM harness and component side INSTALL a new BECM . REFER to Battery
connectors for: Energy Control Module (BECM) in this section.
♦ corrosion. TEST the system for normal operation.
• Connect the BECM and make sure the No
connectors seat correctly. The system is operating correctly at this time.
• Enter the following diagnostic mode on the The concern may have been caused by a loose or
scan tool: Clear DTCs - BECM . corroded connector. CLEAR the DTCs.
• Enter the following diagnostic mode on the REPEAT the self-test. TEST the system for
scan tool: Self-Test - BECM . normal operation.
• Is the original DTC stilesent?
Pinpoint Test F: DTCs P0A8B:64

Normal Operation
once after the ignition was cycled to ON), the Electronically Controlled Continuously Variable Transmission
(eCVT) engages the generator (also in the eCVT ), which charges the High Voltage Traction Battery (HVTB)
and supplies high-voltage to the DC to DC Converter Control Module (DC/DC). The DC/DC charges the
low-voltage battery which is used to power the PCM and low voltage components. The DC/DC steps the high
voltage down to 12 volts (operating range of 13.3-14.7 volts). This DTC may indicate a low state-of-charge in
the 12-volt battery or a Battery Energy Control Module (BECM) fault. If the 12-volt battery has recently had
the terminals disconnected/cleaned or if a new 12-volt battery has been recently installed, this DTC will also
be set. When a fault is present, the system will attempt to continue normal operation. There is no warning
indicator for this fault.
• DTC P0A8B:64 (14 Volt Power Module System Voltage: Signal Plausibility) - Fault sets when
voltage less than 2.5 volts or greater than 25 volts on the BECM input circuit is detected.

• 12-volt battery
• Circuitry
• BECM
PINPOINT TEST F: DTC P0A8B:64

F1 CHECK FOR 12-VOLT INPUT
Yes
• Ignition ON. No
• Measure the voltage between BECM VERIFY the Smart Junction Box (SJB) fuse 17
C4237A-47, circuit SBB17 (RD), harness (10A) is OK. If the fuse is OK, REPAIR the
side and ground; and between BECM circuit. If not OK, REFER to the Wiring Diagrams
C4237A-48, circuit SBB17 (RD), harness manual to identify the possible causes of the circuit
side and ground. short. CLEAR the DTCs. REPEAT the self-test.

F2 CHECK FOR GROUND CIRCUIT


• Measure the resistance between BECM GO to F3 .
C4237A-49, circuit GD126 (BK/WH),
harness side and ground; and between No
BECM C4237A-50, circuit GD126 REPAIR the circuit(s) as necessary. CLEAR the
(BK/WH), harness side and ground. DTCs. REPEAT the self-test. TEST the system for
normal operation.

F3 CHECK FOR CORRECT BECM
OPERATION
Yes
• Check the BECM harness and component INSTALL a new BECM . REFER to Battery
side connectors for: Energy Control Module (BECM) in this section.
♦ corrosion. TEST the system for normal operation.
connectors seat correctly. The system is operating correctly at this time. The
• Operate the system and determine if the concern may have been caused by a loose or
concern is still present. corroded connector. CLEAR the DTCs. REPEAT
• Is the concern still present? the self-test. TEST the system for normal
operation.
Pinpoint Test G: DTC P0A9D:00 or P0A9E:00
Normal Operation
With the ignition in the ON position and the engine running or OFF, the Battery Pack Sensor Module (BPSM)
monitors the High Voltage Traction Battery (HVTB) internal temperature. The BPSM communicates the
HVTB temperature (in addition to other information) to the Battery Energy Control Module (BECM) through
a dedicated Controller Area Network (CAN). There is also a HVTB inlet air temperature sensor mounted to
the inlet air duct which monitors inlet air temperature to the HVTB . The BECM uses the information from
the various temperature sensors to control and maintain HVTB temperature by controlling the HVTB cooling
fan. The ideal HVTB temperature is 25°C (77°F) with a desired range of 20°C (68°F) to 30°C (86°F).
• P0A9D:00 (Hybrid Battery Temperature Sensor A Circuit Low: No Sub Type Information) - Fault
sets if BECM senses an open or short to ground in the thermistor circuitry.
• P0A9E:00 (Hybrid Battery Temperature Sensor A Circuit High: No Sub Type Information) - Fault
sets if BECM senses a short to power in the thermistor circuitry.

• HVTB
PINPOINT TEST F: DTC P0A8B:64 5526

• BPSM
PINPOINT TEST G: DTCs P0A9D:00 OR P0A9E:00
WARNING: Always inspect gloves before each use to prevent high-voltage shock. High-voltage
insulated safety gloves with a leather outer glove are required to service some components of this
vehicle where specified in the service procedures. All high-voltage insulated safety gloves must meet or
exceed ANSI/ASTM class 00. Refer to Rubber Insulating Gloves Testing in this section. Failure to
follow these instructions may result in serious personal injury or death.
Result / Action to
Test Step
Take
G1 MEASURE THERMISTOR RESISTANCE FROM BPSM
Yes
WARNING: Always wear high-voltage insulated safety gloves with GO to G2 .
leather outer gloves and a face shield when servicing the battery pack
sensor module (BPSM) and never remove the high-voltage BPSM No
connector unless directed by a service procedure. High voltage is INSTALL a HVTB
present at the BPSM at all times, even with service disconnect plug (includes HVTB
removal . Depowering the system will not remove voltage from the system wire harness).
BPSM connector with the orange harness. Follow all service REFER to
instructions. Failure to follow these instructions may result in serious High-Voltage
personal injury or death. Traction Battery in
the section. CLEAR
WARNING: Never install the service disconnect plug when a the DTCs. REPEAT
high-voltage service cover is removed. Always install the cover prior the self-test. TEST
to connecting the service disconnect plug. The cover prevents the system for
inadvertent contact with the high voltage which is present at several normal operation.
points under the cover. Failure to follow these instructions may result
in serious personal injury or death.
• Ignition OFF.
• Depower the HVTB system. Refer to High-Voltage Traction Battery
Systems Depowering in this section.
• Remove the high-voltage Bussed Electrical Center (BEC) cover. Refer to
the exploded view in Battery Pack Sensor Module (BPSM) in this section.
• Disconnect: BPSM C4238B.
• Measure the resistance between BPSM C4238B-2, circuit J2-B2, harness
side and BPSM C4238B-13, circuit J2-B13, harness side. Use the
following table to determine if the resistance values are correct.

Temperature Range Resistance Range

-30°C (-22°F) to -21°C (-5°F) 132,571 ohms - 76,491 ohms
-20°C (-4°F) to -11°C (13°F) 77,380 ohms - 46,573 ohms
-10°C (14°F) - 0°C (32°F) 46,762 ohms - 27,965 ohms
0°C (32°F) - 10°C (51°F) 29,164 ohms - 18,115 ohms
11°C (52°F) - 20°C (68°F) 17,931 ohms - 12,037 ohms
21°C (69°F) - 30°C (86°F) 11,842 ohms - 8,155 ohms
31°C (87°F) - 40°C (104°F) 7,850 ohms - 5,624 ohms
41°C (105°F) - 50°C (122°F) 5,602 ohms - 3,957 ohms
• Is the resistance value correct for the temperature?

G2 CHECK THERMISTOR FOR A SHORT TO GROUND
Yes
• Measure the resistance between BPSM C4238B-2, circuit J2-B2, harness INSTALL a new
side and the battery case. BPSM . REFER to
Battery Pack Sensor
Module (BPSM) in
this section. CLEAR
the DTCs. REPEAT
the self-test. TEST
the system for
normal operation.
No
INSTALL a HVTB
(includes HVTB
system wire harness).
REFER to
High-Voltage
Traction Battery in
the section. CLEAR
the DTCs. REPEAT
the self-test. TEST
the system for
normal operation.
Pinpoint Test H: DTC P0AA1:00 or P0AA2:00
PINPOINT TEST G: DTCs P0A9D:00 OR P0A9E:00 5528

Normal Operation
When the ignition is turned on, the Battery Energy Control Module (BECM) makes various vehicle checks. If
these checks are normal, the BECM sends a signal to the contactor to close and supply high-voltage power to
the vehicle. The stop safely hazard (red triangle) warning indicator will illuminate for both DTCs. For DTC
P0AA1:00, the vehicle will not start at next ignition cycle. For P0AA2:00, the vehicle is shut down.
• DTC P0AA1:00 (Hybrid Battery Positive Contactor Circuit Stuck Closed: No Sub Type Information)
- If the contactor is stuck closed, this DTC will be set.
• DTC P0AA2:00 (Hybrid Battery Positive Contactor Circuit Stuck Open: No Sub Type Information) -
If the contactor is stuck open for 2 seconds, this DTC will be set. Reports as a continuous memory
(historical) DTC only.

• BECM
• High Voltage Traction Battery (HVTB)
PINPOINT TEST H: DTC P0AA1:00 OR P0AA2:00
WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings service
instructions, including instructions to depower the system. The high-voltage system utilizes

H1 MEASURE VOLTAGE AT THE BECM CONNECTOR
Yes
• Measure the voltage between BECM C4237B-58, circuit
J1-A58, harness side and ground by back-probing the BECM No
connector. INSTALL a new BECM . REFER
to Battery Energy Control Module
(BECM) in this section. CLEAR
operation.
• Is the voltage between 5-6 volts?

H2 MEASURE VOLTAGE AT THE BECM CONNECTOR

• Measure the voltage between BECM C4237B-58, circuit Yes

J1-A58, harness side and BECM C4237B-59, circuit J1-A59, GO to H3 .
harness side by back-probing the BECM connector.
No
INSTALL a new BECM . REFER
operation.

H3 CHECK CONTACTOR WIRING
Yes
WARNING: Never install the service disconnect plug INSTALL a new high-voltage
when a high-voltage service cover is removed. Always BEC . REFER to High-Voltage
install the cover prior to connecting the service disconnect Bussed Electrical Center in this
plug. The cover prevents inadvertent contact with the section. CLEAR the DTCs.
high voltage which is present at several points under the REPEAT the self-test. TEST the
cover. Failure to follow these instructions may result in system for normal operation.
serious personal injury or death.
No
• Ignition OFF. INSTALL a new HVTB (includes
• Depower the HVTB system. Refer to High-Voltage Traction HVTB system wire harness).
Battery Systems Depowering in this section. REFER to High-Voltage Traction
• Disconnect the 12-volt battery. Refer to Section 414-01 . Battery in this section. CLEAR
• Remove the high-voltage BEC cover. Refer to the exploded the DTCs. REPEAT the self-test.
view in Battery Pack Sensor Module (BPSM) in this section. TEST the system for normal
• Disconnect: BECM C4237B. operation.
• Disconnect: High-voltage BEC C4236D.
• Measure the resistance between high-voltage BEC
C4236D-1, circuit J1-A58, harness side and BECM
C4237B-58, circuit J1-A58, harness side; and between
high-voltage BEC C4236D-2, circuit J1-A59 harness side
and BECM C4237B-59, circuit J1-A59, harness side.
Pinpoint Test I: DTC P0AA4:00 or P0AA5:00
PINPOINT TEST H: DTC P0AA1:00 OR P0AA2:00 5530

Normal Operation
these checks are normal, the BECM sends a signal to the contactor to close which will supply power to the
vehicle. The stop safely hazard (red triangle) warning indicator will illuminate for both DTCs. For DTC
P0AA4:00, the vehicle will not start at the next ignition cycle. For P0AA5:00, the vehicle is shut down.
• DTC P0AA4:00 (Hybrid Battery Negative Contactor Circuit Stuck Closed: No Sub Type Information)
- If the contactor is stuck closed, this DTC will be set. Reports as a continous memory (historical)
DTC only.
• DTC P0AA5:00 (Hybrid Battery Negative Contactor Circuit Stuck Open: No Sub Type Information) -
If the contactor is stuck open for 2 seconds, this DTC will be set.

• BECM
PINPOINT TEST I: DTC P0AA4:00 OR P0AA5:00
high-voltage cables and wiring are identified by orange harness tape or orangee covering. All

I1 MEASURE VOLTAGE AT THE BECM CONNECTOR
Yes
• Measure voltage between BECM C4237B-55, circuit J1-A55
harness side and ground, by back-probing the BECM No
connector. INSTALL a new BECM . REFER
operation.

I2 MEASURE VOLTAGE AT THE BECM CONNECTOR


• Measure voltage between BECM C4237B-55, circuit J1-A55, GO to I3 .
harness side, and BECM C4237B-56, circuit J1-A56, harness
side, by back-probing the BECM connector. No
INSTALL a new BECM . REFER
operation.

I3 CHECK CONTACTOR WIRING
Yes
WARNING: Never install the service disconnect plug INSTALL a new high-voltage
when a high-voltage service cover is removed. Always BEC . REFER to High-Voltage
install the cover prior to connecting the service disconnect Bussed Electrical Center in this
plug. The cover prevents inadvertent contact with the section. CLEAR the DTCs.
high voltage which is present at several points under the REPEAT the self-test. TEST the
cover. Failure to follow these instructions may result in system for normal operation.
No
• Ignition OFF. INSTALL a new HVTB (includes
• Depower the HVTB system. Refer to High-Voltage Traction HVTB system wire harness).
Battery Systems Depowering in this section. REFER to High-Voltage Traction
• Disconnect the 12-volt battery Refer to Section 414-01 . Battery in this section. CLEAR
• Remove the high-voltage BEC cover. Refer to the exploded the DTCs. REPEAT the self-test.
view in Battery Pack Sensor Module (BPSM) in this section. TEST the system for normal
• Disconnect: BECM C4237B. operation.
C4236D-7, circuit J1-A55, harness side and BECM
C4237B-55, circuit J1-A55, harness side; and between
high-voltage BEC C4236D-8, circuit J1-A56, harness side
and BECM C4237B-56, circuit J1-A56, harness side.
Pinpoint Test J: DTC P0AA6:00
PINPOINT TEST I: DTC P0AA4:00 OR P0AA5:00 5532

Normal Operation
With the ignition in the ON position and the engine running or OFF (the engine must have run at least once
after the ignition was cycled to ON), the Battery Energy Control Module (BECM) monitors the electrical
isolation (leakage resistance) between the high-voltage system and the vehicle chassis. A resistance value of
less than 147,000 ohms is a failure. There are 2 types of failures. A mild fault will only illuminate the
powertrain malfunction (wrench) warning indicator. A severe fault will illuminate the stop safely hazard (red
triangle) warning indicator and the vehicle will not start at the next ignition cycle. The normal resistance value
is between 950,000-1,330,000+ ohms.
• DTC P0AA6:00 (Hybrid Battery Voltage System Isolation Fault: No Sub Type Information) - If the
BECM detects a high-voltage system leakage this DTC will be set. If the BECM detects a
high-voltage system severe leakage, the vehicle will not restart and the BECM will set this DTC.
This pinpoint is intended to diagnose the following:

• Electronically Controlled Continuously Variable Transmission (eCVT)
• Moisture/water penetration of high-voltage connectors
• A/C compressor
PINPOINT TEST J: DTC P0AA6:00
service instructions, including instructions to depower the system. Theigh-voltage system utilizes
NOTE: If DTC P0A78 or DTC P0A7A is present in the Transmission Control Module (TCM), diagnose
those DTCs first. Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.

J1 MONITOR THE LEAKAGE RESISTANCE PIDs
Yes
• Ignition ON. CLEAR the DTCs. REPEAT the
• Connect the scan tool. self-test. If the DTC is not present at this
• Enter the following diagnostic mode on the scan tool: time, INSPECT the high-voltage system
Clear DTCs - BECM . for any physical damage. With the
• NOTE: Clear the BECM DTCs or the vehicle may service plug disconnected, INSPECT the
not start. high-voltage cables between the HVTB
• Start the engine. and eCVT and between HVTB and
• Enter the following diagnostic mode on the scan tool: DC/DC or A/C compressor for chafing or
DataLogger - BECM . damaged insulation. If damage is found,
• With the engine running, monitor the following INSTALL new-high voltage cables.
BECM PIDs: REFER to High-Voltage Cables in this
section. If no damage was found,

♦ Leakage Resistance (Bus+) PID RETURN the vehicle to the customer.

(LEAKRESPOS)
♦ Leakage Resistance (Bus-) PID No
(LEAKRESNEG) GO to J2 .
♦ Leakage Resistance (Overall) PID
(LEAKRESALL)
• Do the PIDs read greater than 147,000 ohms for at
least 10 seconds?
J2 CHECK THE HVTB TO TCM HIGH-VOLTAGE
CABLES
Yes
WARNING: Never install the service disconnect GO to J3
plug when a high-voltage service cover is removed.
Always install the cover prior to connecting the No
service disconnect plug. The cover prevents INSTALL new high-voltage cables.
inadvertent contact with the high voltage which is REFER to High-Voltage Cables in this
present at several points under the cover. Failure section.
to follow these instructions may result in serious
personal injury or death.
• Ignition OFF.
• Depower the HVTB system. Refer to High-Voltage
Traction Battery Systems Depowering in this section.
• Disconnect the 12-volt battery. Refer to Section
414-01 .
• Disconnect: High-Voltage Bussed Electrical Center
(BEC) C4236B.
• Disconnect: TCM C1458C.
C4236B-3, circuit HYT04 (OG/BK), harness side and
ground; and between high-voltage BEC C4236B-4,
circuit HYT03 (OG/BK), harness side and ground
while performing a wiggle test of the high-voltage
cables.

J3 CHECK THE ACCM AND DC/DC HIGH VOLTAGE
CABLES
Yes
• Disconnect: ACCM C1469B. GO to J4 .
• Disconnect: High-Voltage BEC C4236A.
• Disconnect: DC/DC C1457A. No
• Measure the resistance between DC/DC C1457A-2, INSTALL new high-voltage cables.
circuit HYT03 (OG/WH), harness side and ground; REFER to High-Voltage Cables in this
and between DC/DC C1457A-1, circuit HYT04 section. CLEAR the DTCs. REPEAT the
PINPOINT TEST J: DTC P0AA6:00 5534

(OG/BK), harness side and ground while performing a self-test. TEST the system for normal
wiggle test of the high-voltage cables. operation.

J4 CHECK THE DC/DC
Yes
• Measure the resistance between DC/DC C1457 pin 1, GO to J5 .
component side and ground; and between DC/DC
C1457 pin 2, component side and ground. No
INSTALL a new DC/DC . REFER to
DC/DC in this section. CLEAR the

J5 CHECK THE ACCM
Yes
• Measure the resistance between Air Conditioning GO to J6 .
Compressor Module (ACCM) C1469B pin 1,
component side and ground; and between ACCM No
C1469B pin 2, component side and ground. INSTALL a new ACCM and A/C
compressor assembly. REFER to Section
412-01 . CLEAR the DTCs. REPEAT
operation.

J6 CHECK THE TCM
Yes
• Measure the resistance between Transmission Control GO to J7 .
Module (TCM) C1458C pin 3, component side and
ground; and between TCM C1458C pin 4, component No
side and ground. INSTALL a new Electronically
Controlled Continuously Variable
Transmission (eCVT). REFER to Section

307-01C . CLEAR the DTCs. REPEAT

operation.

J7 CHECK THE HIGH-VOLTAGE CABLES
Yes
• Install new high-voltage cables. Refer to Repair is complete. TEST the system for
High-Voltage Cables in this section. normal operation.
• Connect: Service Disconnect Plug. No
• Ignition ON. GO to J8 .
Clear DTCs - BECM .
• NOTE: Clear the BECM DTCs or the vehicle may
not start.
DataLogger - BECM .
• With the engine running, monitor the following
BECM PIDs:
♦ Leakage Resistance (Bus+) PID
(LEAKRESPOS)
♦ Leakage Resistance (Bus-) PID
(LEAKRESNEG)
(LEAKRESALL)
least 10 seconds?
J8 CHECK THE DC/DC
Yes
WARNING: Never install the service disconnect Repair is complete. TEST the system for
plug when a high-voltage service cover is removed. normal operation.
Always install the cover prior to connecting the
service disconnect plug. The cover prevents No
inadvertent contact with the high voltage which is GO to J9 .
present at several points under the cover. Failure
• Ignition OFF.
414-01 .
• Ignition ON.


Clear DTCs - BECM .
not start.
DataLogger - BECM .
BECM PIDs:
(LEAKRESPOS)
(LEAKRESNEG)
(LEAKRESALL)
least 10 seconds?
J9 CHECK THE ACCM
Yes
inadvertent contact with the high voltage which is GO to J10 .
present at several points under the cover. Failure
• Ignition OFF.
414-01 .
• Install a new ACCM . Refer to Section 412-01 .
• Ignition ON.
Clear DTCs - BECM .
not start.
DataLogger - BECM .
• With the engine running, monitor the foing BECM
PIDs:
(LEAKRESPOS)
(LEAKRESNEG)
(LEAKRESALL)
least 10 seconds?

J10 CHECK THE HVTB

Yes
inadvertent contact with the high voltage which is INSTALL a new eCVT . REFER to
present at several points under the cover. Failure Section 307-01C . CLEAR the DTCs.
to follow these instructions may result in serious REPEAT the self-test. TEST the system
personal injury or death. for normal operation.
• Ignition OFF.
414-01 .
• Install a new HVTB . Refer to High-Voltage Traction
• Ignition ON.
Clear DTCs - BECM .
not start.
DataLogger - BECM .
BECM PIDs:
(LEAKRESPOS)
(LEAKRESNEG)
(LEAKRESALL)
least 10 seconds?
Pinpoint Test K: DTC P0AAE:00 or P0AAF:00
Normal Operation

• P0AAE:00 (Hybrid Battery Pack Air Temperature Sensor A Circuit Low: No Sub Type Information) -
Fault sets if the BECM senses greater than 90°C (194°F) from the HVTB inlet air temperature sensor
for 10 seconds or more. Extreme ambient temperatures could also set this DTC.
• P0AAF:00 (Hybrid Battery Pack Air Temperature Sensor A Circuit High: No Sub Type Information)
- Fault sets if the BECM senses less than -45°C (-49°F) from the HVTB inlet airensor for 10 seconds
or more. Extreme ambient temperatures could also set this DTC.

• BECM
• HVTB
PINPOINT TEST K: DTC P0AAE:00 OR P0AAF:00
Result /
Test Step Action to
Take
K1 MEASURE THERMISTOR RESISTANCE FROM BECM
671 ohms
WARNING: Never install the service disconnect plug when a high-voltage - 469
service cover is removed. Always install the cover prior to connecting the ohms
service disconnect plug. The cover prevents inadvertent contact with the high
voltage which is present at several points under the cover. Failure to follow
these instructions may result in serious personal injury or death.
• Ignition OFF.
• Depower the HVTB system. Refer to High-Voltage Traction Battery Systems
Depowering in this section.
• Remove the high-voltage Bussed Electrical Center (BEC) cover. Refer to the
exploded view in Battery Pack Sensor Module (BPSM) in this section.
• Disconnect: Battery Energy Control Module (BECM) C4237B.
• Measure the resistance between BECM C4237B-39, circuit J1-A39, harness side and
BECM C4237B-41, circuit J1-A41, harness side. Use the following table to
determine if the resistance values are correct.

-30°C (-22°F) to -20°C (-5°F) 52,594 ohms - 28,582 ohms
-20°C (-4°F) to -10°C (13°F) 28,582 ohms - 16,120 ohms
PINPOINT TEST K: DTC P0AAE:00 OR P0AAF:00 5539

-10°C (14°F) - 0°C (32°F) 16,120 ohms - 9,399 ohms

0°C (32°F) - 10°C (51°F) 9,399 ohms - 5,685 ohms
10°C (52°F) - 20°C (68°F) 5,685 ohms - 3,511 ohms
20°C (69°F) - 30°C (86°F) 3,511 ohms - 2,240 ohms
30°C (87°F) - 40°C (104°F) 2,240 ohms - 1,465 ohms
40°C (105°F) - 50°C (122°F) 1,465 ohms - 980 ohms
50°C (122°F) - 60°C (140°F) 980 ohms - 671 ohms
Yes
GO to K3 .
No
GO to K2 . K2 MEASURE THERMISTOR RESISTANCE AT THE THERMISTOR
• Disconnect: HVTB Inlet Air Temperature Sensor C4253.

• Measure the resistance between HVTB inlet air temperature sensor C4253 pin 1 and pin 2, component
side. Use the following table to determine if the resistance values are correct.
Resistance Range
-30°C (-22°F) to -20°C (-5°F) 52,594 ohms - 28,582 ohms
-20°C (-4°F) to -10°C (13°F) 28,582 ohms - 16,120 ohms
-10°C (14°F) - 0°C (32°F) 16,120 ohms - 9,399 ohms
0°C (32°F) - 10°C (51°F) 9,399 ohms - 5,685 ohms
10°C (52°F) - 20°C (68°F) 5,685 ohms - 3,511 ohms
20°C (69°F) - 30°C (86°F) 3,511 ohms - 2,240 ohms
30°C (87°F) - 40°C (104°F) 2,240 ohms - 1,465 ohms
40°C (105°F) - 50°C (122°F) 1,465 ohms - 980 ohms
50°C (122°F) - 60°C (140°F) 980 ohms - 671 ohms
60°C (140°F) - 70°C (158°F) 671 ohms - 469 ohms
PINPOINT TEST K: DTC P0AAE:00 OR P0AAF:00 5540

Yes
INSTALL a new HVTB (includes HVTB system wire harness). REFER to High-Voltage Traction Battery in
the section. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
No
INSTALL a new HVTB inlet air temperature thermistor. REFER to High-Voltage Traction Battery Inlet Air
Temperature Sensor in the section. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal
operation. K3 CHECK FOR CORRECT BECM OPERATION
• Ignition OFF.
• Check the BECM harness and component side connectors for:
♦ corrosion.
• Connect the BECM and make sure the connectors seat correctly.
• Operate the system and determine if the concern is still present.
Yes
INSTALL a new BECM . REFER to Battery Energy Control Module (BECM) in this section. CLEAR the
DTCs. REPEAT the self-test. TEST the system for normal operation.
No
connector. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
Pinpoint Test L: DTC P0ABC:00
Normal Operation
The Battery Pack Sensor Module (BPSM) monitors battery pack voltage using voltage sensors within the
High Voltage Traction Battery (HVTB). The BPSM communicates normal pack voltage to the Battery Energy
Control Module (BECM) via a dedicated Controller Area Network (CAN). Nominal voltage should be
between 179-343 volts.
• P0ABC:00 (Hybrid Battery Pack Voltage Sense A Circuit Low: No Sub Type Information) - Fault is
set when BPSM senses voltage less than 172 volts for 1 second or more.

• BPSM
• HVTB

PINPOINT TEST l: DTC P0ABC:00

l1 RETRIEVE ALL BECM DTCs
Yes
• Connect the scan tool. REFER to the Battery
• Ignition ON. Energy Control Module
• Enter the following diagnostic mode on the scan tool: Self Test - (BECM) DTC Chart and
BECM . diagnose all other DTCs
• Do any DTCs other than P0ABC:00 exist? first.
No
GO to L2 .
l2 INSTALL A NEW BPSM
Yes
WARNING: Always wear high-voltage insulated safety gloves INSTALL a new HVTB
with leather outer gloves and a face shield when servicing the (includes HVTB system
battery pack sensor module (BPSM) and never remove the wire harness). REFER to
high-voltage BPSM connector unless directed by a service High-Voltage Traction
procedure. High voltage is present at the BPSM at all times, even Battery in this section.
with service disconnect plug removal . Depowering the system will CLEAR the DTCs.
not remove voltage from the BPSM connector with the orange REPEAT the self-test.
harness. Follow all service itructions. Failure to follow these TEST the system for
instructions may result in serious personal injury or death. normal operation.
WARNING: Never install the service disconnect plug when a No

high-voltage service cover is removed. Always install the cover The repair is now
prior to connecting the service disconnect plug. The cover complete. CLEAR the
prevents inadvertent contact with the high voltage which is DTCs. REPEAT the
present at several points under the cover. Failure to follow these self-test. TEST the
instructions may result in serious personal injury or death. system for normal
operation.
• Ignition OFF.
• Install a new BPSM . Refer to Battery Pack Sensor Module (BPSM)
in this section.
• Ignition ON.
• Enter the following diagnostic mode on the scan tool: Clear DTCs -
PINPOINT TEST l: DTC P0ABC:00 5542

BECM .
• Enter the following diagnostic mode on the scan tool: Self Test -
BECM .
• Is DTC P0ABC:00 retrieved?
Pinpoint Test M: DTC P0ABD:00
Normal Operation
The Battery Pack Sensor Module (BPSM) monitors battery pack voltage using voltage sensors within the
High Voltage Traction Battery (HVTB). The BPSM communicates normal pack voltage which should be
between 179-343 volts.
• P0ABD:00 (Hybrid Battery Pack Voltage Sense A Circuit High: No Sub Type Information) - Fault is
set when BPSM senses voltage greater than 350 volts.

• BPSM
• HVTB
PINPOINT TEST M: DTC P0ABD:00

M1 RETRIEVE ALL BECM DTCs
Yes
• Connect the scan tool. REFER to the Battery Energy
• Ignition ON. Control Module (BECM) DTC
• Enter the following diagnostic mode on the scan tool: Self Test Chart and diagnose all other
- BECM . DTCs first.
• Do any DTCs other than P0ABD:00 exist?
No
GO to M2 .
M2 INSTALL A NEW BPSM
Yes

WARNING: Always wear high-voltage insulated safety INSTALL a new HVTB

gloves with leather outer gloves and a face shield when (includes HVTB system wire
servicing the battery pack sensor module (BPSM) and harness). REFER to
never remove the high-voltage BPSM connector unless High-Voltage Traction Battery
directed by a service procedure. High voltage is present at in this section. CLEAR the
the BPSM at all times, even with service disconnect plug DTCs. REPEAT the self-test.
removal . Depowering t system will not remove voltage TEST the system for normal
from the BPSM connector with the orange harness. Follow operation.
all service instructions. Failure to follow these instructions
may result in serious personal injury or death. No
The repair is now complete.
WARNING: Never install the service disconnect plug CLEAR the DTCs. REPEAT
when a high-voltage service cover is removed. Always the self-test. TEST the system
install the cover prior to connecting the service disconnect for normal operation.
plug. The cover prevents inadvertent contact with the high
voltage which is present at several points under the cover.
Failure to follow these instructions may result in serious
• Ignition OFF.
• Install a new BPSM . Refer to Battery Pack Sensor Module
(BPSM) in this section.
• Ignition ON.
• Enter the following diagnostic mode on the scan tool: Clear
DTCs - BECM .
• Enter the following diagnostic mode on the scan tool: Self Test
- BECM .
• Is DTC P0ABD:00 retrieved?
Pinpoint Test N: DTC P0AC7:00 or P0AC8:00
Normal Operation
• P0AC7:00 (Hybrid Battery Temperature Sensor B Circuit Low: No Sub Type Information) - Fault
• P0AC8:00 (Hybrid Battery Temperature Sensor B Circuit High) - Fault sets if BECM senses an short
to power in the thermistor circuitry.
PINPOINT TEST M: DTC P0ABD:00 5544

• HVTB
• BPSM
PINPOINT TEST N: DTCs P0A7:00 OR P0AC8:00

N1 MEASURE THERMISTOR RESISTANCE FROM BPSM
Yes
WARNING: Always wear high-voltage insulated safety GO to N2 .
gloves with leather outer gloves and a face shield when
servicing the battery pack sensor module (BPSM) and never No
remove the high-voltage BPSM connector unless directed by a INSTALL a new HVTB
service procedure. High voltage is present at the BPSM at all (includes HVTB system
times, even with service disconnect plug removal . Depowering wire harness). REFER to
the system will not remove voltage from the BPSM connector High-Voltage Traction
Battery in the section.
with the orange harness. Follow all service instructions. Failure
to follow these instructions may result in serious personal CLEAR the DTCs.
injury or death. REPEAT the self-test.
WARNING: Never install the service disconnect plug when operation.
a high-voltage service cover is removed. Always install the
cover prior to connecting the service disconnect plug. The
cover prevents inadvertent contact with the high voltage which
is present at several points under the cover. Failure to follow
these instructions may result in serious personal injury or
death.
• Ignition OFF.
• Remove the high-voltage Bussed Electrical Center (BEC) cover.
Refer to the exploded view in Battery Pack Sensor Module
• Measure the resistance between BPSM C4238B-25, circuit J2-B25,
harness side and BPSM C4238B-36, circuit J2-B36, harness side.

Use the following table to determine if the resistance values are

correct.

-30°C (-22°F) to -21°C (-5°F) 132,571 ohms - 76 ohms
-20°C (-4°F) to -11°C (13°F) 77,380 ohms - 46,573 ohms
-10°C (14°F) - 0°C (32°F) 46,762 ohms - 27,965 ohms
0°C (32°F) - 10°C (51°F) 29,164 ohms - 18,115 ohms
11°C (52°F) - 20°C (68°F) 17,931 ohms - 12,037 ohms
21°C (69°F) - 30°C (86°F) 11,842 ohms - 8,155 ohms
31°C (87°F) - 40°C (104°F) 7,850 ohms - 5,624 ohms
41°C (105°F) - 50°C (122°F) 5,602 ohms - 3,957 ohms

N2 CHECK THERMISTOR FOR A SHORT TO GROUND
Yes
• Measure the resistance between BPSM C4238B-25, circuit J2-B25, INSTALL a new BPSM .
harness side and the battery case. REFER to Battery Pack
Sensor Module (BPSM) in
this section. CLEAR the
DTCs. REPEAT the
self-test. TEST the system
No
INSTALL a HVTB
(includes HVTB system
wire harness). REFER to
High-Voltage Traction
CLEAR the DTCs.
operation.
Pinpoint Test O: DTC P0ACC:00 or P0ACD:00
PINPOINT TEST N: DTCs P0A7:00 OR P0AC8:00 5546

Normal Operation
• P0ACC:00 (Hybrid Battery Temperature Sensor C Circu: No Sub Type Information) - Fault sets if
BECM senses an open or short to ground in the thermistor circuitry.
• P0ACD:00 (Hybrid Battery Temperature Sensor C Circuit High: No Sub Type Information) - Fault
sets if BECM senses an short to power in the thermistor circuitry.

• BPSM
• HVTB
PINPOINT TEST O: DTC P0ACC:00 OR P0ACD:00

O1 MEASURE THERMISTOR RESISTANCE FROM BPSM
Yes
WARNING: Always wear high-voltage insulated safety GO to O2 .
with the orange harness. Follow all service instructions. Failure Battery in the section.
operation.

WARNING: Never install the service disconnect plug when

death.
• Ignition OFF.
correct.

-30°C (-22°F) to -21°C (-5°F)
132,571 ohms - 76,491 ohms
-20°C (-4°F) to -11°C (13°F)77,380 ohms - 46,573 ohms
-10°C (14°F) - 0°C (32°F) 46,762 ohms - 27,965 ohms
0°C (32°F) - 10°C (51°F) 29,164 ohms - 18,115 ohms
11°C (52°F) - 20°C (68°F) 17,931 ohms - 12,037 ohms
21°C (69°F) - 30°C (86°F) 11,842 ohms - 8,155 ohms
7,850 ohms - 5,624 ohms
41°C (105°F) - 50°C (122°F) 5,602 ohms - 3,957 ohms

O2 CHECK THERMISTOR FOR A SHORT TO GROUND
Yes
• the resistance between BPSM C4238B-3, circuit J2-B3, harness INSTALL a new BPSM .
side and the battery case. REFER to Battery Pack
DTCs. REPEAT the
PINPOINT TEST O: DTC P0ACC:00 OR P0ACD:00 5548

No
INSTALL a HVTB
CLEAR the DTCs.
operation.
Pinpoint Test P: DTC P0AD9:00
Normal Operation
high-voltage vehicle systems. The Battery Pack Sensor Module (BPSM) monitors the battery voltage from
inside the High Voltage Traction Battery (HVTB) and the high-voltage Bussed Electrical Center (BEC). If
there is no high voltage to the positive contactor, the BECM will set the DTC and shut down the vehicle. The
stop safely hazard (red triangle) warning indicator will illuminate.
• P0AD9:00 (Hybrid Battery Positive Contactor Control Circuit Open/GM: No Sub Type Information) -
If there is no high voltage to the positive contactor, this DTC will be set.

• BECM
• High-voltage BEC
• HVTB
PINPOINT TEST P: DTC P0AD9:00
NOTICE: Use the correct probe adapter(s) from the Flex Probe Kit when taking measurements. Flure

P1 MEASURE CONTACTOR RESISTANCE
Yes
WARNING: Never install the service disconnect plug GO to P2 .
when a high-voltage service cover is removed. Always

install the cover prior to connecting the service disconnect No

plug. The cover prevents inadvertent contact with the high INSTALL a new high-voltage
voltage which is present at several points under the cover. BEC . REFER to High-Voltage
Failure to follow these instructions may result in serious Bussed Electrical Center in this
personal injury or death. section. CLEAR the DTCs.
• Remove the high-voltage BEC cover. Refer to the exploded
view in Battery Pack Sensor Module (BPSM) in this section.
• Measure the resistance between the:
♦ BEC C4236D pin 1 and pin 2, component side.
♦ BEC C4236D pin 4 and pin 5, component side.
• Are the resistances between 5-50 ohms?
P2 CHECK CONTACTOR RESISTOR
Yes
• With the service disconnect plug removed, measure the GO to P3 .
resistance of the precharge resistor in the BEC .
No
INSTALL a new high-voltage
BEC . REFER to High-Voltage
Bussed Electrical Center in this
• Is the resistance between 6-10 ohms?

P3 MEASURE CIRCUIT RESISTANCE
Yes
• Disconnect: BECM C4237B. GO to P4 .
• Measure the resistance between the high-voltage BEC
C4236D-1, circuit J1-A58, harness side and BECM No
C4237B-58, circuit J1-A58, harness side. INSTALL a new HVTB
• Measure the resistance between the high-voltage BEC (includes HVTB system wire
C4236D-2, circuit J1-A59, harness side, and BECM harness). REFER to
C4237B-59, circuit J1-A59, harness side. High-Voltage Traction Battery in
this section.

normal operation.
PINPOINT TEST P: DTC P0AD9:00 5550


P4 CHECK FOR OPEN IN CIRCUIT
Yes
• Measure the resistance between high-voltage BEC C4236D, GO to P5 .
harness side and BECM C4237B, harness side as follows:
No
INSTALL a new HVTB
(includes HVTB system wire
harness). REFER to
High-Voltage BEC Circuit BECM High-Voltage Traction Battery in
C4236D-4 J1-A61 C4237B-61 this section. CLEAR the DTCs.
C4236D-5 J1-A62 C4237B-62 system for normal operation.

P5 CHECK FOR CORRECT BECM OPERATION
Yes
• Ignition OFF. INSTALL a new BECM .
• Check the BECM harness and component side connectors for: REFER to Battery Energy
♦ corrosion. Control Module (BECM) in this
♦ pushed-out/bent pins. section. CLEAR the DTCs.
• Connect the BECM and make sure the connectors seat REPEAT the self-test. TEST the
correctly. system for normal operation.
• Operate the system and determine if the concern is still
present. No
• Is the concern still present? The system is operating correctly
at this time. The concern may
have been caused by a loose or
corroded connector. CLEAR the
operation.
Pinpoint Test Q: DTC P0ADD:00
PINPOINT TEST P: DTC P0AD9:00 5551

Normal Operation
inside the High Voltage Traction Battery (HVTB) and compares it to voltage on the high-voltage Bussed
Electrical Center (BEC) contactors. If there is no high voltage to the negative contactor, the BECM will set
the DTC and shut down the vehicle. The stop safely hazard (red triangle) warning indicator will illuminate
and the vehicle will shut down.
• P0ADD:00 (Hybrid Battery Negative Contactor Control Circuit Open: No Sub Type Information) - If
there is no high voltage to the negative contactor, this DTC will be set.

• BECM
• HVTB
PINPOINT TEST Q: DTC P0ADD:00

Q1 MEASURE CONTACTOR RESISTANCE
Yes
WARNING: Never install the service disconnect plug GO to Q2 .
plug. The cover prevents inadvertent contact with the INSTALL a new high-voltage
high voltage which is present at several points under the BEC . REFER to High-Voltage
cover. Failure to follow these instructions may result in Bussed Electrical Center in this
serious personal injury or death. section. CLEAR the DTCs.
• Measure the resistance between high-voltage BEC C4236D
pin 7 and pin 8, component side.
Q2 MEASURE CIRCUIT RESISTANCE

• Disconnect: BECM C4237B. Yes

• Measure the resistance between: GO to Q3 .
♦ high-voltage BEC C4236D-7, circuit J1-A55, harness
side and BECM C4237B-55, circuit J1-A55, harness No
side. INSTALL a new HVTB (includes
♦ high-voltage BEC C4236D-8, circuit J1-A56, harness HVTB system wire harness).
side and BECM C4237B-56, circuit J1-A56, harness REFER to High-Voltage Traction
side. Battery in this section.

normal operation.

Q3 CHECK FOR CORRECT BECM OPERATION
Yes
• Ignition OFF. INSTALL a new BECM . REFER
• Check the BECM harness and component side connectors to Battery Energy Control
for: Module (BECM) in this section.
♦ corrosion. CLEAR the DTCs. REPEAT the
♦ pushed-out/bent pins. self-test. TEST the system for
• Connect the BECM and make sure the connectors seat normal operation.
correctly.
• Operate the system and determine if the concern is still No
present. The system is operating correctly
• Is the concern still present? at this time. The concern may
operation.
Pinpoint Test R: DTC P0ADA:00 or P0ADE:00
Normal Operation
inside the High Voltage Traction Battery (HVTB) and the high-voltage Bussed Electrical Center (BEC). The
powertrain malfunction (wrench) warning indicator will be illuminated when a fault is present.
• P0ADA:00 (Hybrid Battery Positive Contactor Control Circuit Range/Performance: No Sub Type
Information) - This DTC will set if positive contactor voltage is below or above 179-343 volts for 1
second or more.
• P0ADE:00 (Hybrid Battery Negative Contactor Control Circuit Range/Performance: No Sub Type
PINPOINT TEST Q: DTC P0ADD:00 5553

Information) - This DTC will set if voltage at the negative contactor is below or above 179-343 volts
for 1 second or more.
This pinpoint test is inte to diagnose the following:

• BPSM
• HVTB
PINPOINT TEST R: DTC P0ADA:00 OR P0ADE:00

R1 RETRIEVE ALL BECM DTCs
Yes
• Connect the scan tool. REFER to the Battery Energy
• Ignition ON. Control Module (BECM) DTC Chart
• Enter the following diagnostic mode on the scan tool: Self and diagnose all other DTCs first.
Test - BECM .
• Do any DTCs other than P0ADA:00 or P0ADE:00 No
exist? GO to R2 .
R2 INSTALL A NEW HIGH-VOLTAGE BEC
Yes
WARNING: Never install the service disconnect GO to R3 .
plug when a high-voltage service cover is removed.
Always install the cover prior to connecting the service No
disconnect plug. The cover prevents inadvertent The repair is now complete. CLEAR
contact with the high voltage which is present at the DTCs. REPEAT the self-test.
several points under the cover. Failure to follow these TEST the system for normal
instructions may result in serious personal injury or operation.
death.
• Ignition OFF.
• Install a new high-voltage BEC . Refer to High-Voltage
Bussed Electrical Center in this section.
• Ignition ON.
Clear DTCs - BECM .
• Enter the following diagnostic mode on the scan tool: Self
Test - BECM .
• Did DTC P0ADA:00 or P0ADE:00 return?
R3 INSTALL A NEW BPSM

WARNING: Never install the service disconnect Yes

plug when a high-voltage service cover is removed. INSTALL a new HVTB (includes
Always install the cover prior to connecting the service HVTB system wire harness). REFER
disconnect plug. The cover prevents inadvertent to High-Voltage Traction Battery in
contact with the high voltage which is present at the section. CLEAR the DTCs.
several points under the cover. Failure to follow these REPEAT the self-test. TEST the
instructions may result in serious personal injury or system for normal operation.
death.
No
• Ignition OFF. The repair is now complete. CLEAR
• Depower the HVTB system. Refer to High-Voltage the DTCs. REPEAT the self-test.
Traction Battery Systems Depowering in this section. TEST the system for normal
• Install a new BPSM . Refer to Battery Pack Sensor operation.
Module (BPSM) in this section.
• Ignition ON.
• Using the scan tool, clear any BECM DTCs.
Clear DTCs - BECM .
• Enter the following diagnostic mode on the scan tool: Self
Test - BECM .
• Did DTC P0ADA:00 or P0ADE:00 return?
Pinpoint Test S: DTC P0AEA:00 or P0AEB:00
Normal Operation
• P0AEA:00 (Hybrid Battery Temperature Sensor D Circuit Low: No Sub Type Information) - Fault
• P0AEB:00 (Hybrid Battery Temperature Sensor D Circuit High: No Sub Type Information) - Fault
sets if the BECM senses a short to power in the thermistor circuitry.

• BPSM
• HVTB
PINPOINT TEST S: DTC P0AEA:00 OR P0AEB:00
PINPOINT TEST R: DTC P0ADA:00 OR P0ADE:00 5555


S1 MEASURE THERMISTOR RESISTANCE FROM BPSM
Yes
WARNING: Always wear high-voltage insulated safety GO to S2 .
with the orange harness. Follow all service instructions. Failure
WARNING: Never install the service disconnect plug when operation.
death.
• Ignition OFF.
correct.

-30°C (-22°F) to -21°C (-5°F) 132,571 ohms - 76,491 ohms
-20°C (-4°F) to -11°C (13°F) 77,380 ohms - 46,573 ohms
PINPOINT TEST S: DTC P0AEA:00 OR P0AEB:00 5556

-10°C (14°F) - 0°C (32°F) 46,762 ohms - 27,965 ohms

0°C (32°F) - 10°C (51°F) 29,164 ohms - 18,115 ohms
11°C (52°F) - 20°C (68°F) 17,931 ohms - 12,037 ohms
21°C (69°F) - 30°C (86°F) 11,842 ohms - 8,155 ohms
31°C (87°F) - 40°C (104°F) 7,850 ohms - 5,624 ohms
41°C (105°F) - 50°C (122°F) 5,602 ohms - 3,957 ohms

S2 CHECK THERMISTOR FOR A SHORT TO GROUND
Yes
• Measure the resistance between BPSM C4238B-27, circuit J2-B27, INSTALL a new BPSM .
harness side and the battery case. REFER to Battery Pack
DTCs. REPEAT the
No
INSTALL a HVTB
CLEAR the DTCs.
operation.
Pinpoint Test T: DTC P0AC0:00, P0AC1:00 or P0AC2:00
Normal Operation
The Battery Pack Sensor Module (BPSM) measures current flow through the contactors using current sensors
mounted within the Bussed Electrical Center (BEC). The BPSM uses a 5-volt reference to the current sensors
and measures the return voltage. This return voltage is translated into current flow by the BPSM . This
information is communicated to the Battery Energy Control Module (BECM) via a dedicated Controller Area
Network (CAN).

• P0AC0:00 (Hybrid Battery Pack Current Sensor A Circuit Range/Performance: No Sub Type
Information) - Fault is set when the reference voltage offset is outside the normal range.
• P0AC1:00 (Hybrid Battery Pack Current Sensor A Circuit Low: No Sub Type Information) - Fault is
set when the reference voltage is below 0.25 volt.
• P0AC2:00 (Hybrid Battery Pack Current Sensor A Circuit High: No Sub Type Information) - Fault is
set when the reference voltage is above 4.75 volt.

• BECM
• BPSM
PINPOINT TEST T: DTC P0AC0:00, P0AC1:00 OR P0AC2:00
Result / Action to
Test Step
Take
T1 RETRIEVE ALL BECM DTCs
Yes
• Connect the scan tool. GO to T2
• Ignition ON.
• Enter the following diagnostic mode on the scan tool: Self Test - BECM . No
• Is DTC P0B10:00 present? GO to T4 .
T2 MEASURE VOLTAGE AT CURRENT SENSOR CONNECTOR
Yes
WARNING: Never install the service disconnect plug when a GO to T4 .
high-voltage service cover is removed. Always install the cover prior
to connecting the service disconnect plug. The cover prevents No
inadvertent contact with the high voltage which is present at several GO to T3 .
• Ignition OFF.
PINPOINT TEST T: DTC P0AC0:00, P0AC1:00 OR P0AC2:00 5558

• Remove the high-voltage BEC cover. Refer to the exploded view in

Battery Pack Sensor Module (BPSM) in this section.
• Disconnect: High-voltage BEC C4236E.
• Ignition ON.
• Measure the voltage between high-voltage BEC C4236E-B, circuit
J2-B12, harness side and high-voltage BEC C4236E-C, circuit J2-B1,
harness side.

T3 CHECK CURRENT SENSOR CIRCUITS
Yes
WARNING: Always wear high-voltage insulated safety gloves INSTALL a new
with leather outer gloves and a face shield when servicing the battery BPSM . REFER to
pack sensor module (BPSM) and never remove the high-voltage Battery Pack Sensor
BPSM connector unless directed by a service procedure. High voltage Module (BPSM) in
is present at the BPSM at all times, even with service disconnect plug this section. CLEAR
removal . Depowering the system will not remove voltage from the the DTCs. REPEAT
BPSM connector with the orange harness. Follow all service the self-test. TEST
instructions. Failure to follow these instructions may result in serious the system for normal
personal injury or death. operation.
• Ignition OFF. No
• Disconnect: BPSM C4238B. INSTALL a new
• With the service disconnect plug removed, measure the resistance HVTB (includes
between high-voltage BEC C4236E-B, circuit J2-B12, harness side and HVTB system wire
BPSM C4238B-12, circuit J2-B27, harness side; and between harness). REFER to
high-voltage BEC C4236E-C, circuit J2-B1, harness side and BPSM High-Voltage
C4238B-1, circuit J2-B1, harness side. Traction Battery in
this section. CLEAR
the DTCs. REPEAT
the self-test. TEST
operation.

T4 MEASURE VOLTAGE AT BPSM CONNECTOR

WARNING: Always wear high-voltage insulated safety gloves Yes

with leather outer gloves and a face shield when servicing the battery INSTALL a new
pack sensor module (BPSM) and never remove the high-voltage BPSM . REFER to
BPSM connector unless directed by a service procedure. High voltage Battery Pack Sensor
is present at the BPSM at all times, even with service disconnect plug Module (BPSM) in
removal . Depowering the system will not remove voltage from the this section. CLEAR
BPSM connector with the orange harness. Follow all service the DTCs. REPEAT
instructions. Failure to follow these instructions may result in serious the self-test. TEST
personal injury or death. the system for normal
operation.
WARNING: Never install the service disconnect plug when a
high-voltage service cover is removed. Always install the cover prior No
to connecting the service disconnect plug. The cover prevents GO to T5 .
inadvertent contact with the high voltage which is present at several
• Ignition OFF.
• If not previously removed, remove the high-voltage BEC cover. Refer to
• Connect: BEC C4236E (if previously disconnected).
• Ignition ON.
• With the service disconnect plug removed, measure the voltage between
BPSM C4238B-35, circuit J2-B35, harness side and ground by
back-probing the BPSM connector.

T5 CHECK CURRENT SENSOR SIGNAL CIRCUIT
Yes
with leather outer gloves and a face shield when servicing the battery high-voltage BEC .
pack sensor module (BPSM) and never remove the high-voltage REFER to
BPSM connector unless directed by a service procedure. High voltage High-Voltage Bussed
is present at the BPSM at all times, even with service disconnect plug Electrical Center in
removal . Depowering the system will not remove voltage from the this section. CLEAR
BPSM connector with the orange harness. Follow all service the DTCs. REPEAT
instructions. Failure to follow these instructions may result in serious the self-test. TEST
personal injury or death. the system for normal
operation.
• Ignition OFF.
• Disconnect: BPSM C4238B. No
• With the service disconnect plug removed, measure the resistance INSTALL a new
between high voltage BEC C4236E-D, circuit J2-B35, harness side and HVTB (includes

BPSM C4238B-35, circuit J2-B35, harness side. HVTB system wire

harness). REFER to
High-Voltage
Traction Battery in
this section. CLEAR
the DTCs. REPEAT
the self-test. TEST
operation.
Pinpoint Test U: DTC P0ADC:00
Normal Operation
these checks are normal, the BECM sends a signal to the contactor to close which will supply high-voltage
power to the vehicle. If an overcurrent condition is sensed by the BECM , the stop safely hazard (red triangle)
warning indicator is illuminated and the vehicle will shut down and/or not start.
• P0ADC:00 (Hybrid Battery Positive Contactor Control Circuit High: No Sub Type Information) - If
the BECM detects overcurrent on the contactor control circuit for 1 second or more, this DTC will be
set. Reports as a continuous memory (historical) DTC only.

• BECM
PINPOINT TEST U: DTC P0ADC:00
Failure to follow these instructions may relt in serious personal injury or death.

Result / Action to
Test Step
Take
U1 CHECK FOR SHORT IN CIRCUIT
Yes
• Ignition OFF. INSTALL a new HVTB
• Disconnect: BECM C4237B. (includes HVTB system
• Ignition ON. wire harness). REFER
• Measure the voltage between BECM C4237B-58, circuit J1-A58, to High-Voltage
harness side and ground; and between BECM C4237B-59, circuit Traction Battery in this
J1-A59, harness side and ground. section. CLEAR the
DTCs. REPEAT the
self-test. TEST the
system for normal
operation.
No
GO to U2 .

U2 MEASURE CONTACTOR COIL RESISTANCE
Yes
WARNING: Always inspect gloves before each use to prevent GO to U3 .
high-voltage shock. High-voltage insulated safety gloves with a
leather outer glove are required to service some components of this No
vehicle where specified in the service procedures. All high-voltage INSTALL a new
insulated safety gloves must meet or exceed ANSI/ASTM class 00. high-voltage BEC .
Refer to Rubber Insulating Gloves Testing in this section. Failure REFER to
to follow these instructions may result in serious personal injury orHigh-Voltage Bussed
death. Electrical Center in this
section. CLEAR the
WARNING: Never install the service disconnect plug when a DTCs. REPEAT the
high-voltage service cover is removed. Always install the cover self-test. TEST the
prior to connecting the service disconnect plug. The cover prevents system for normal
inadvertent contact with the high voltage which is present at operation.
several points under the cover. Failure to follow these instructions
may result in serious personal injury or death.
• Ignition OFF.
• Measure the resistance between high-voltage BEC C4236D pin 1 and
pin 2, component side.
U3 CHECK FOR CORRECT BECM OPERATION
Yes
• Check the BECM harness and component side connectors for: BECM . REFER to
♦ corrosion. Battery Energy Control
PINPOINT TEST U: DTC P0ADC:00 5562

♦ pushed-out/bent pins. Module (BECM) in this

• Connect the BECM and make sure the connectors seat correctly. section. CLEAR the
• Connect: High-Voltage BEC C4236D. DTCs. REPEAT the
• Install the high-voltage BEC cover. Refer to the exploded view in self-test. TEST the
Battery Pack Sensor Module (BPSM) in this section. system for normal
• Connect: Service Disconnect Plug. operation.
• Operate the system and determine if the concern is still present.
• Is the concern still present? No
correctly at this time.
The concern may have
been caused by a loose
or corroded connector.
CLEAR the DTCs.
TEST the system for
normal operation.
Pinpoint Test V: DTC P0AFB:00
Normal Operation
During vehicle operation, the High Voltage Traction Battery (HVTB) normal operating voltage range is
between 179-343 volts. The electrical system is monitored by the Battery Energy Control Module (BECM)
and Battery Pack Sensor Module (BPSM). As the voltage is used in the HVTB , a request to charge the battery
is sent on the High Speed Controller Area Network (HS-CAN) to the Electronically Controlled Continuously
Variable Transmission (eCVT) to send voltage to the battery to charge the battery and bring the operating
voltage back to peak operating conditions. If battery voltage becomes too high, an over-charge condition is
indicated. When battery voltage is too high, the stop safely hazard (red triangle) warning indicator is
illuminated and the vehicle will shut down.
• P0AFB:00 (Hybrid Battery System Voltage High: No Sub Type Information) - Fault sets if the HVTB
voltage is high for 10 seconds or more.

• BECM
• BPSM
PINPOINT TEST V: DTC P0AFB:00

V1 RETRIEVE ALL BECM DTCs
Yes
• Connect the scan tool. REFER to the Battery Energy Control Module (BECM)
• Ignition ON. DTC Chart and diagnose all other DTCs first.
• Enter the following diagnostic
mode on the scan tool: Self Test - No
BECM . GO to V2 .

• Do any DTCs other than

P0AFB:00 exist?
V2 MONITOR BECM PID HYBRID
BATTERY PACK VOLTAGE
(BATPACKVOLT)
Yes
• Monitor BECM PID INSTALL a new BPSM span>. REFER to Battery Pack
BATPACKVOLT. Sensor Module (BPSM) in this section. CLEAR the DTCs.
• Is PIDs BATPACKVOLT below REPEAT the self-test. TEST the system for normal
344 volts? operation.
No
INSTALL a new BECM . REFER to Battery Energy Control
Module (BECM) in this section. CLEAR the DTCs.
operation.
Pinpoint Test W: DTC P0AFD:00
Normal Operation
With the ignition in the ON position and the engine ON or OFF, the Battery Pack Sensor Module (BPSM)
monitors and maintains the High Voltage Traction Battery (HVTB) temperature in a specific range. A
thermistor is mounted to the inlet air duct which monitors inlet air temperature along with thermistors inside
the HVTB which monitor HVTB temperature. The ideal HVTB temperature is 25°C (77°F) with a desired
range of 20°C (68°F) to 30°C (86°F). The HVTB is not designed to operate in temperatures below -40°C
(-40°F). The Battery Energy Control Module (BECM) controls the temperature by adjusting the HVTB
cooling fan speed. The BPSM communicates the HVTB and inlet air temperature to the BECM through a
dedicated Controller Area Network (CAN).
• P0AFD:00 (Hybrid Battery Pack Temperature Too Low: No Sub Type Information) - Fault code sets
if a thermistor within the battery senses temperature inside the battery was -40°C (-40°F).

• BPSM
• HVTB
PINPOINT TEST W: DTC P0AFD:00
PINPOINT TEST V: DTC P0AFB:00 5564


W1 MEASURE THERMISTOR
RESISTANCE FROM BPSM
Yes
WARNING: Always wear INSTALL a new BPSM . REFER to Battery Pack Sensor
high-voltage insulated safety Module (BPSM) in this section. CLEAR the DTCs.
gloves with leather outer gloves REPEAT the self-test. TEST the system for normal
and a face shield when servicing operation.
the battery pack sensor module
(BPSM) and never remove the No
high-voltage BPSM connector INSTALL a new ge Traction Battery" class="popup"
unless directed by a service onmouseover="this.className='popupnounderline';"
procedure. High voltage is onmouseout="this.className='popup';">HVTB (includes
present at the BPSM at all times, HVTB system wire harness). REFER to High-Voltage
even with service disconnect plug Traction Battery in the section. CLEAR the DTCs.
removal . Depowering the system REPEAT the self-test. TEST the system for normal
will not remove voltage from the operation.
BPSM connector with the orange
harness. Follow all service
instructions. Failure to follow
these instructions may result in
WARNING: Never install the

service disconnect plug when a
high-voltage service cover is
removed. Always install the cover
prior to connecting the service
disconnect plug. The cover
prevents inadvertent contact with
the high voltage which is present
at several points under the cover.
Failure to follow these
instructions may result in serious
• Ignition OFF.
• Depower the HVTB system. Refer
to High-Voltage Traction Battery
Systems Depowering in this
section.
• Remove the high-voltage Bussed
Electrical Center (BEC) cover.
Refer to the exploded view in
Battery Pack Sensor Module
PINPOINT TEST W: DTC P0AFD:00 5565

• Measure the resistance of each of

the thermistors located within the
HVTB . Use the following charts to
determine pin location and
expected resistance values.
Connector Pins
Thermistor Connector Pins

Thermistor C4238B 2 and 13
A
Thermistor B C4238B 25 and
36
Thermistor C C4238B 3 and 14
Thermistor C4238B 27 and
D 38
Thermistor E C4238B 26 and
37
Resistance
Temperature Range Range
-30°C (-22°F) to 132,571
-21°C (-5°F) ohms -
76,491
ohms
-20°C (-4°F) to -11°C
(13°F) 77,380 ohms -
46,573 ohms
-10°C (14°F) - 0°C 46,762
(32°F) ohms -
27,965
ohms
0°C (32°F) - 10°C 29,164
(51°F) ohms -
18,115
ohms
11°C (52°F) - 20°C 17,931
(68°F) ohms -
12,037
ohms
21°C (69°F) - 30°C 11,842
(86°F) ohms -
8,155 ohms
31°C (87°F) - 40°C 7,850 ohms
(104°F) - 5,624
ohms
PINPOINT TEST W: DTC P0AFD:00 5566

41°C (105°F) - 50°C 5,602 ohms

(122°F) - 3,957
ohms
• Are the resistance values correct

for the temperature?
Pinpoint Test X: DTC P0B10:00 or P0B12:00
Normal Operation
The Battery Pack Sensor Module (BPSM) measures current flow through the contactors using current sensors
mounted within the Bussed Electrical Center (BEC). The BPSM uses a 5-volt reference to the current sensors
and measures the return voltage. This return voltage is translated into current flow by the BPSM .
• P0B10:00 (Hybrid Battery Pack Current Sensor B Circuit Low: No Sub Type Information) - Fault is
set when the reference voltage is below 0.25 volt.
• P0B12:00 (Hybrid Battery Pack Current Sensor B Circuit Intermittent/Erratic: No Sub Type
Information) - Fault is set when the reference voltage is outside of the normal 0.25-4.75 volt range.

• BPSM
PINPOINT TEST X: DTC P0B10:00 OR P0B12:00
approximately 300 volts DC, provided throhigh-voltage cables to its components and modules. The
WARNING: Always wear high-voltage insulated safety gloves with leather outer gloves and a face
shield when servicing the battery pack sensor module (BPSM) and never remove the high-voltage
BPSM connector unless directed by a service procedure. High voltage is present at the BPSM at all
times, even with service disconnect plug removal . Depowering the system will not remove voltage from
the BPSM connector with the orange harness. Follow all service instructions. Failure to follow these
instructions may result in serious personal injury or death.

Result / Action to
Test Step
Take
X1 RETRIEVE ALL BECM DTCs
Yes
• Connect the scan tool. GO to X2 .
• Ignition ON.
• Enter the following diagnostic mode on the scan tool: Self Test - BECM . No
• Is DTC P0B10:00 present? GO to X4 .
X2 MEASURE VOLTAGE AT CURRENT SENSOR CONNECTOR
Yes
WARNING: Never install the service disconnect plug when a GO to X4 .
inadvertent contact with the high voltage which is present at several GO to X3 .
• Ignition OFF.
• Disconnect: High-voltage BEC C4236E.
• Ignition ON.
• Measure the voltage between high-voltage BEC C4236E-B, circuit
J2-B12, harness side and high-voltage BEC C4236E-C, circuit J2-B1,
harness side.

X3 CHECK CURRENT SENSOR CIRCUITS
Yes
with leather outer gloves and a face shield when servicing the battery BPSM . REFER to
pack sensor module (BPSM) and never remove the high-voltage Battery Pack Sensor
BPSM connector unless directed by a service procedure. High voltage Module (BPSM) in
is present at the BPSM at all times, even with service disconnect plug this section. CLEAR
removal . Depowering the system will not remove voltage from the the DTCs. REPEAT
BPSM connector with the orange harness. Follow all service the self-test. TEST
instructions. Failure to follow these instructions may result in serious the system for normal
personal injury or death. operation.
PINPOINT TEST X: DTC P0B10:00 OR P0B12:00 5568

• Disconnect: BPSM C4238B. No

• With the service disconnect plug removed, measure the resistance INSTALL a new
between high-voltage BEC C4236E-B, circuit J2-B12, harness side and HVTB (includes
BPSM C4238B-12, circuit J2-B12, harness side; and between HVTB system wire
high-voltage BEC C4236E-C, circuit J2-B1, harness side and BPSM harness). REFER to
C4238B-1, circuit J2-B1, harness side. High-Voltage
Traction Battery in
this section. CLEAR
the DTCs. REPEAT
the self-test. TEST
operation.

X4 MEASURE VOLTAGE AT BPSM CONNECTOR
Yes
WARNING: Always inspect gloves before each use to prevent INSTALL a new
high-voltage shock. High-voltage insulated safety gloves with a BPSM . REFER to
leather outer glove are required to service some components of this Battery Pack Sensor
vehicle where specified in the service procedures. All high-voltage Module (BPSM) in
insulated safety gloves must meet or exceed ANSI/ASTM class 00. this section. CLEAR
Refer to Rubber Insulating Gloves Testing in this section. Failure to the DTCs. REPEAT
follow these instructions may result in serious personal injury or the self-test. TEST
death. the system for normal
operation.
high-voltage service cover is removed. Always install the cover prior No
to connecting the service disconnect plug. The cover prevents GO to X5 .
• Ignition OFF.
• If not previously removed, remove the high-voltage BEC cover. Refer to
• Connect: High-voltage BEC C4236E (if previously disconnected).
• Ignition ON.
BPSM C4238B-24, circuit J2-B24, harness side and ground by
back-probing the Battery Energy Control Module (BECM) connector.
PINPOINT TEST X: DTC P0B10:00 OR P0B12:00 5569


X5 CHECK CURRENT SENSOR SIGNAL CIRCUIT
Yes
• Disconnect: BPSM C4238B. high-voltage BEC .
• With the service disconnect plug removed, measure the resistance REFER to
between high-voltage BEC C4236E-A, circuit J2-B24, harness side and High-Voltage Bussed
BPSM C4238B-24, circuit J2-B24, harness side. Electrical Center in
this section. CLEAR
the DTCs. REPEAT
the self-test. TEST
operation.
No
INSTALL a new
HVTB (includes
HVTB system wire
harness). REFER to
High-Voltage
Traction Battery in
this section. CLEAR
the DTCs. REPEAT
the self-test. TEST
operation.
Pinpoint Test Y: DTC P0B1B:00
Normal Operation
The Battery Pack Sensor Module (BPSM) monitors battery pack voltage by measuring voltage within the
High Voltage Traction Battery (HVTB). The BPSM then broadcasts the voltage value via the dedicated
Controller Area Network (CAN) to the BECM . Normal pack voltage should be between 179-343 volts.
• P0B1B:00 (Hybrid Battery Pack Voltage Sense C Circuit Low: No Sub Type Information) - Fault is
set when BPSM senses low voltage.

• HVTB
• BPSM
PINPOINT TEST Y: DTC P0B1B:00

Y1 RETRIEVE THE BECM DTCs
Yes

• Connect the scan tool. REFER to the Battery Energy Control Module (BECM) DTC
• Ignition ON. Chart and diagnose all other DTCs first.
mode on the scan tool: Clear No
DTCs - BECM . GO to Y2 .
mode on the scan tool: Self Test -
BECM .
• Are any DTCs other than
P0B1B:00 retrieved?
Y2 INSTALL A NEW BPSM
Yes
• Ignition OFF. GO to Y3 .
• Install a new BPSM . Refer to
Battery Pack Sensor Module No
(BPSM) in this section. REPAIR is complete. CLEAR the DTCs. REPEAT the
• Ignition ON. self-test. TEST the system for normal operation.
mode on the scan tool: Clear
DTCs - BECM .
BECM .
• Is DTC P0B1B:00 retrieve
Y3 INSTALL A NEW BECM
Yes
• Ignition OFF. INSTALL a new HVTB (includes HVTB system wire
• Install a new BECM . Refer to harness). REFER to High-Voltage Traction Battery in this
Battery Energy Control Module section. CLEAR the DTCs. REPEAT the self-test. TEST the
(BECM) in this section. system for normal operation.
• Ignition ON.
• Enter the following diagnostic No
mode on the scan tool: Clear REPAIR is complete. CLEAR the DTCs. REPEAT the
DTCs - BECM . self-test. TEST the system for normal operation.
BECM .
• Is DTC P0B1B:00 retrieved?
Pinpoint Test Z: DTC P0BC4:00 or P0BC5:00
Normal Operation
PINPOINT TEST Y: DTC P0B1B:00 5571

• P0BC4:00 (Hybrid Battererature Sensor E Circuit Low: No Sup Type Information) - Fault sets if the
BECM senses an open or short to ground in the thermistor circuitry.
• P0BC5:00 (Hybrid Battery Temperature Sensor E Circuit High: No Sub Type Information) - Fault
sets if the BECM senses an short to power in the thermistor circuitry.

• BPSM
• HVTB
PINPOINT TEST Z: DTC P0BC4:00 OR P0BC5:00
Failure to follow these instructions may result in serious personal injury or death. WARNING:
Always inspect gloves before each use to prevent high-voltage shock. High-voltage insulated safety
gloves with a leather outer glove are required to service some components of this vehicle where
specified in the service procedures. All high-voltage insulated safety gloves must meet or exceed
ANSI/ASTM class 00. Refer to Rubber Insulating Gloves Testing in this section. Failure to follow these
Result / Action to
Test Step
Take
Z1 MEASURE THERMISTOR RESISTANCE FROM BPSM
Yes
WARNING: Always wear high-voltage insulated safety gloves with GO to Z2 .
connector unless directed by a service procedure. High voltage is INSTALL a new
present at the BPSM at all times, even with service disconnect plug HVTB (includes
removal . Depowering the system will not remove voltage from the HVTB system wire
BPSM connector with the orange harness. Follow all service harness). REFER to
this section.
WARNING: Never install the service disconnect plug when a CLEAR the DTCs.
high-voltage service cover is removed. Always install the cover prior to REPEAT the
connecting the service disconnect plug. The cover prevents inadvertent self-test. TEST the
contact with the high voltage which is present at several points under system for normal
the cover. Failure to follow these instructions may result in serious operation.
• Ignition OFF.


• Measure the resistance between BPSM C4238B-26, circuit J2-B26, harness
side and BPSM C4238B-37, circuit J2-B37, harness side. Use the following
table to determine if the resistance values are correct.
Temperature
Range Resistance Range
-30°C (-22°F) to 132,571 ohms - 76,491 ohms
-21°C (-5°F)
-20°C (-4°F) to 77,380 ohms - 46,573 ohms
-11°C (13°F)
-10°C (14°F) - 0°C 46,762 ohms - 27,965 ohms
(32°F)
0°C (32°F) - 10°C 29,164 ohms - 18,115 ohms
(51°F)
11°C (52°F) - 20°C 17,931 ohms - 12,037 ohms
(68°F)
21°C (69°F) - 30°C 11,842 ohms - 8,15D valign="top" 7,850 ohms
(86°F) align="center">31°C (87°F) - 40°C - 5,624
(104°F) ohms
41°C (105°F) - 5,602 ohms - 3,957 ohms
50°C (122°F)

Z2 CHECK THERMISTOR FOR A SHORT TO GROUND r>
Yes
• Measure the resistance between BPSM C4238B-26, circuit J2-B26, harness INSTALL a new
side and the battery case. BPSM . REFER to
Battery Pack Sensor
Module (BPSM) in
this section.
CLEAR the DTCs.
REPEAT the
self-test. TEST the
system for normal
operation.
No
PINPOINT TEST Z: DTC P0BC4:00 OR P0BC5:00 5573

INSTALL a HVTB
(includes HVTB
system wire
harness). REFER to
High-Voltage
Traction Battery in
the section. CLEAR
the DTCs. REPEAT
the self-test. TEST
the system for
normal operation.
Pinpoint Test AA: DTC P1A0A:11, P1A0A:12 or P1A0A:15
Normal Operation
The Transmission Control Module (TCM) monitors immediate shutdown inputs from the Battery Energy
Control Module (BECM). When the TCM detects an input out of the expected range, the BECM will set this
DTC.
• P1A0A:11 (Immediate Shutdown Signal A: Circuit Short to Ground) - This DTC is set when the rapid
shutdown circuit A is shorted to ground for 2 secos or more.
• P1A0A:12 (Immediate Shutdown Signal A: Circuit Short to Battery) - This DTC is set when the rapid
shutdown circuit is shorted to battery for 1 second or more. This DTC sets during vehicle shutdown
and reports as a continuous memory (historical) DTC only.
• P1A0A:15 (Immediate Shutdown Signal A: Circuit Short to Battery or Open) - This DTC is set when
the circuit is shorted to battery or open for 2 seconds or more.

• BECM
• TCM
PINPOINT TEST AA: DTCs P1A0A:11, P1A0A:12 OR P1A0A:15

AA1 CHECK CIRCUIT FOR SHORT TO GROUND
Yes
• Ignition OFF. GO to AA2 .
• Disconnect: TCM C1458A. No
• Measure the resistance of BECM C4215, circuit REPAIR the circuit. CLEAR the DTCs.
CYB16 (BN/VT), harness side and ground. REPEAT the self-test. TEST the system


AA2 CHECK CIRCUIT FOR SHORT TO BATTERY
Yes
• Ignition ON. REPAIR the circuit. CLEAR the DTCs.
• Measure the voltage between BECM C4237A-15, REPEAT the self-test. TEST the system
circuit CYB16 (BN/VT), harness side and ground. for normal operation.
No
GO to AA3 .

AA3 CHECK CIRCUIT FOR AN OPEN
Yes
• Ignition OFF. For DTC P1A0A:11 and P1A0A:12, GO
• Measure the resistance between BECM C4237A-15, to AA4 .
circuit CYB16 (BN/VT), harness side and TCM
C1458A-6 circuit CYB16 (BN/VT), harness side. For DTC P1A0A:15, GO to AA5 .
No
REPAIR the circuit. CLEAR the DTCs.

AA4 RETRIEVE BECM DTCs
Yes
• Connect: BECM C4237A (leave TCM C1458A GO to AA6 .
disconnected). No
• Connect the scan tool. CARRY OUT self-test of the TCM and
• Ignition ON. REFER to Powertrain Control/Emissions
• Enter the following diagnostic mode on the scan tool: Diagnosis (PC/ED) manual for diagnosis
Clear DTCs - BECM . of TCM DTCs.
Self Test - BECM .
• NOTE: When retrieving DTCs with TCM C1458A
disconnected, DTC P1A0A:15 would normally be
present.
PINPOINT TEST AA: DTCs P1A0A:11, P1A0A:12 OR P1A0A:15 5575

• Is DTC P1A0A:11 or P1A0A:12 retrieved?

AA5 RETRIEVE BECM DTCs WHILE GROUNDING
CIRCUIT
Yes
• Connect: BECM C4237A. GO to AA6 .
• Connect a fused jumper wire between TCM
C1458A-6, circuit CYB16 (BN/VT), harness side No
and ground. CARRY OUT self-test of the TCM and
REFER to Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis
of TCM DTCs.
If no DTCs are retrieved, INSTALL a new

Electronically Controlled Continuously
Variable Transmission (eCVT). REFER to
Section 307-01C .

• Ignition ON.
Clear DTCs - BECM .
Self Test - BECM .
• NOTE: When retrieving DTCs with TCM C1458A
-6 shorted to ground, DTC P1A0A:11 would
normally be present.
• Is DTC P1A0A:15 retrieved?
AA6 CHECK FOR CORRECT BECM OPERATION
Yes
• Ignition OFF. INSTALL a new BECM . REFER to
• Check the BECM harness and component side Battery Energy Control Module (BECM)
connectors for: in this section. CLEAR the DTCs.
♦ corrosion. REPEAT the self-test. TEST the system
♦ pushed-out/bent pins. for normal operation.
• Connect the BECM and make sure the connectors
seat correctly. No
• Connect: TCM C1458A. The system is operating correctly at this
• Operate the system and determine if the concern is time. The concern may have been caused
still present. by a loose or corroded connector. CLEAR
• Is the concern still present? the DTCs. REPEAT the self-test. TEST
Pinpoint Test AB: DTC P1A15:11, P1A15:12 or P1A15:15
Normal Operation
The Transmission Control Module (TCM) monitors immediate shutdown inputs from the Battery Energy
Control Module (BECM). When the TCM detects an input out of the expected range, the BECM will set this
DTC.

• P1A15:11 (Immediate Shutdown Signal B: Circuit Short to Ground) - This DTC is set when the
circuit is shorted to ground.
• P1A15:12 (Immediate Shutdown Signal B: Circuit Short to Battery) - This DTC is set when the
circuit is shorted to battery. This DTC sets during vehicle shutdown and reports as a continuous
memory (historical) DTC only.
• P1A15:15 (Immediate Shutdown Signal B: Circuit Short to Battery or Open) - This DTC is set when
the circuit is shorted to battery or open.
This pinpoint test is intended to diagnose the following: span title="Battery Energy Control
Module" class="popup" onmouseover="this.className='popupnounderline';"
onmouseout="this.className='popup';">BECM
• Electronically Controlled Continuously Variable Transmission (eCVT)
PINPOINT TEST AB: DTCs P1A15:11, P1A15:12 OR P1A15:15

AB1 CHECK CIRCUIT FOR SHORT TO
GROUND
Yes
• Ignition OFF. GO to AB2 .
• Disconnect: TCM C1458B. No
• Measure the resistance of BECM REPAIR the circuit. CLEAR the DTCs. REPEAT
C4237A-29, circuit CYB17 (BU/GY), the self-test. TEST the system for normal operation.

ohms?
AB2 CHECK CIRCUIT FOR SHORT TO
BATTERY
Yes
• Ignition ON. REPAIR the circuit. CLEAR the DTCs. REPEAT
• Measure the voltage between BECM the self-test. TEST the system for normal operation.
C4237A-29, circuit CYB17 (BU/GY),
GO to AB3 .
PINPOINT TEST AB: DTCs P1A15:11, P1A15:12 OR P1A15:15 5577


AB3 CHECK CIRCUIT FOR AN OPEN
Yes
• Ignition OFF. For DTC P1A15:11 and P1A15:12, GO to AB4 .
• Measure the resistance between BECM
C4237A-29, circuit CYB17 (BU/GY), For DTC P1A15A:15, GO to AB5 .
harness side and TCM C1458B-7, circuit
CYB17 (BU/GY), harness side. No
REPAIR the circuit. CLEAR the DTCs. REPEAT
the self-test. TEST the system for normal operation.

AB4 RETRIEVE BECM DTCs
Yes
• Connect: BECM C4237A (leave TCM GO to AB6 .
C1458B disconnected).
• Connect the scan tool. No
• Ignition ON. CARRY OUT self-test of the TCM and REFER to
• Enter the following diagnostic mode on the Powertrain Control/Emissions Diagnosis (PC/ED)
scan tool: Clear DTCs - BECM . manual for diagnosis of TCM DTCs.
scan tool: Self Test - BECM . If no DTCs are retrieved, INSTALL a new eCVT .
• NOTE: When retrieving DTCs with TCM REFER to Section 307-01C .
C1458AB disconnected, DTC P1A15:15
would normally be present.
• Is DTC P1A15:11 or P1A15:12
retrieved?
AB5 RETRIEVE BECM DTCs
Yes
• Connect: BECM C4237A. GO to AB6 .
• Connect a fused jumper wire between TCM
C1458B-7, circuit CYB17 (BU/GY), No
harness side and ground. CARRY OUT self-test of the TCM and REFER to
manual for diagnosis of TCM DTCs.
PINPOINT TEST AB: DTCs P1A15:11, P1A15:12 OR P1A15:15 5578


• Ignition ON.
scan tool: Clear DTCs - BECM .
scan tool: Self Test - BECM
• NOTE: When retrieving DTCs with TCM
C1458AB-7 shorted to ground, DTC
P1A15:11 would normally be present.
• Is DTC P1A15:15 retrieved?
AB6 CHECK FOR CORRECT BECM
OPERATION
Yes
• Ignition OFF. INSTALL a new BECM . REFER to Battery
• Check the BECM harness and component Energy Control Module (BECM) in this section.
side connectors for: CLEAR the DTCs. REPEAT the self-test. TEST the
♦ corrosion. system for normal operation.
connectors seat correctly. The system is operating correctly at this time. The
• Connect: TCM C1458B. concern may have been caused by a loose or
concern is still present. the self-test. TEST the system for normal operation.
Pinpoint Test AC: DTC B11D8:11
Normal Operation
The Battery Energy Control Module (BECM) monitors the impact notification output from the Restraints
Control Module (RCM). The RCM outputs a Pulse-Width Modulation (PWM) voltage on the circuit based on
status. If an event is indicated, the BECM will initiate shutdown of the High Voltage Traction Battery
(HVTB) system. If the BECM senses a fault on the circuit, it will illuminate the powertrain malfunction
(wrench) warning indicator and set a DTC.
• B11D8:11 (Restraint Event Notification: Circuit Short to Ground) - This DTC sets when the BECM
detects a short to ground on the event notification signal circuit for 5 seconds or more.

• Fuel Pump (FP) control module
• RCM
• BECM

PINPOINT TEST AC: DTC B11D8:11

AC1 CHECK CIRCUIT FOR SHORT
TO GROUND
Yes
• Ignition OFF. GO to AC2 .
• Disconnect: RCM C310A. No
• Disconnect: FP Control Module REPAIR the circuit. CLEAR the DTCs. REPEAT the
C446. self-test. TEST the system for normal operation.
• Measure the resistance of BECM
C4237A-46, circuit CR167 (YE/VT),
harness side to ground.
• Is the resistance greater than

10,000 ohms?
AC2 CHECK BECM DTCs
Yes
• Connect: BECM C4237A. GO to AC3 .
• Connect: RCM C310A.
• Ignition ON. INSTALL a new FP control module. REFER to Section
• Enter the following diagnostic mode 303-04D . CLEAR the DTCs. REPEAT the self-test.
on the scan tool: Clear DTCs - TEST the system for normal operation.
BECM .
on the scan tool: Self Test - BECM .
• Is DTC B11D8:11 retrieved?
AC3 RETRIEVE BECM DTCs
Yes
• Disconnect: RCM C310A.
• Ignition ON. No
• Enter the following diagnostic mode INSTALL a new RCM . REFER to Section 501-20B .
on the scan tool: Clear DTCs - CLEAR the DTCs. REPEAT the self-test. TEST the
BECM . system for normal operation.
on the scan tool: Self Test - BECM .
PINPOINT TEST AC: DTC B11D8:11 5580


AC4 CHECK FOR CORRECT BECM
OPERATION
Yes
• Check the BECM harness and Control Module (BECM) in this section. CLEAR the
component side connectors for: DTCs. REPEAT the self-test. TEST the system for
♦ corrosion. normal operation.
• Connect the BECM and make sure No
the connectors seat correctly. The system is operating correctly at this time. The
• Connect: RCM C310A. concern may have been caused by a loose or corroded
• Connect: Fuel Pump (FP) C446. connector. CLEAR the DTCs. REPEAT the self-test.
• Operate the system and determine if TEST the system for normal operation.
Pinpoint Test AD: DTC B11D8:15
Normal Operation
The Battery Energy Control Module (BECM) monitors the impact notification output from the Restraints
Control Module (RCM). The RCM outputs a Pulse-Width Modulation (PWM) voltage on the circuit based on
status. If an impact notification is indicated, the BECM will initiate shutdown of the High Voltage Traction
Battery (HVTB) system. If the BECM senses a fault on the circuit, it will illuminate the powertrain
malfunction (wrench) warning indicator and set a DTC.
• B11D8:15 (Restraint Event Notification: Circuit Short to Battery or Open) - The DTC sets when the
BECM detects an open or short to voltage on the event notification signal circuit for 5 seconds or
more.

• Circuitry
• Fuel Pump (FP) control module
• RCM
• BECM
PINPOINT TEST AD: DTC B11D8:15

AD1 CHECK CIRCUIT FOR AN OPEN &nb;


• Disconnect: BECM C4237A. GO to AD2 .
• Disconnect: RCM C310A.
• Disconnect: FP Control Module C446. No
• Ignition ON. REPAIR the circuit. CLEAR the DTCs.
• Measure the resistance between BECM REPEAT the self-test. TEST the system for
C4237A-46, circuit CR167 (YE/VT), harness normal operation.
side and RCM C310A-19, circuit CR167

AD2 CHECK CIRCUIT FOR SHORT TO
POWER
Yes
• Ignition OFF. REPAIR the circuit. CLEAR the DTCs.
• Measure the voltage between BECM REPEAT the self-test. TEST the system for
C4237A-46, circuit CR167 (YE/VT), harness normal operation.
side and ground.
No
GO to AD3 .

AD3 CHECK BECM DTCs
Yes
• Connect: BECM C4237A. GO to AD4 .
• Connect: RCM C310A.
• Ignition ON. INSTALL a new FP control module. REFER to
• Enter the following diagnostic mode on the Section 303-04D . CLEAR the DTCs. REPEAT
scan tool: Clear DTCs - BECM . the self-test. TEST the system for normal
• Enter the following diagnostic mode on the operation.
AD4 RETRIEVE BECM DTCs WITH RCM
GROUNDED
PINPOINT TEST AD: DTC B11D8:15 5582


• Disconnect: RCM C310A. GO to AD5 .
• Connect a fused jumper wire between RCM
C310A-19, circuit CR167 (YE/VT), harness No
side and ground. INSTALL a new RCM . REFER to Section
501-20B . CLEAR the DTCs. REPEAT the
• Ignition ON.
scan tool: Clear DTCs - BECM .
• NOTE: When retrieving DTCs with RCM
C310A-19 shorted to ground, DTC B11D8:36
would normally be present.
• Does DTC B11D8:15 appear?
AD5 CHECK FOR CORRECT BECM
OPERATION
Yes
• Connect: RCM C310A. Energy Control Module (BECM) in this section.
• Connect: FP Control Module C446. CLEAR the DTCs. REPEAT the self-test. TEST
• Check the BECM harness and component side the system for normal operation.
connectors for:
♦ corrosion. No
♦ pushed-out/bent pins. The system is operating correctly at this time.
• Connect the BECM and make sure the The concern may have been caused by a loose or
connectors seat correctly. corroded connector. CLEAR the DTCs. REPEAT
• Operate the system and determine if the the self-test. TEST the system for normal
concern is still present. operation.
Pinpoint Test AE: DTC U0074:00 or U1006:00
Normal Operation
During normal vehicle operation the Battery Energy Control Module (BECM) and Battery Pack Sensor
Module (BPSM) communicate with each other providing information each module needs to properly monitor
and control the high-voltage system This communication is done over a dedicated Controller Area Network
(CAN).
• U0074:00 (Control Module Communication Bus "B" Off: No Sub Type Information) - Fault sets if

the BECM detects the dedicated CAN is off.

• U1006:00 (Sub Network CAN Initialization Failure: No Sub Type Information) - Fault sets if the
BECM detects the dedicated CAN hardware does not initialize for 1 second or more.

• BECM
• BPSM
PINPOINT TEST AE: DTC U0074:00 OR U1006:00
WAR: To prevent the risk of high-voltage shock, always follow precisely all warnings and service
instructions, including instructions to depower the system. The high-voltage system utilizes
Result / Action to
Test Step
Take
AE1 CHECK CAN CIRCUITS
Yes
WARNING: Always wear high-voltage insulated safety gloves GO to AE2 .
with leather outer gloves and a face shield when servicing the battery
pack sensor module (BPSM) and never remove the high-voltage No
BPSM connector unless directed by a service procedure. High voltage INSTALL a new
is present at the BPSM at all times, even with service disconnect plug HVTB (includes
instructions. Failure to follow these instructions may result in seriousHigh-Voltage
this section. CLEAR
WARNING: Never install the service disconnect plug when a the DTCs. REPEAT
high-voltage service cover is removed. Always install the cover prior the self-test. TEST
to connecting the service disconnect plug. The cover prevents the system for normal
inadvertent contact with the high voltage which is present at several operation.
• Ignition OFF.
PINPOINT TEST AE: DTC U0074:00 OR U1006:00 5584


• Disconnect: BECM C4237B.
• Measure the resistance between BECM C4237B-2, circuit J1-A02,
harness side and BPSM C4238B-23, circuit J1-A02, harness side; and
between BECM C4237B-18, circuit J1-A18, harness side and BPSM
C4238B-22, circuit J1-A18, harness side.

AE2 CHECK CIRCUITS FOR SHORT TO GROUND
Yes
• Ignition OFF. GO to AE3 .
• Measure the resistance between BECM C4237B-2, circuit J1-A02,
harness side and ground; and between BECM C4237B-18, circuit J1-A18, No
harness side and ground. INSTALL a new
HVTB (includes
HVTB system wire
harness). REFER to
High-Voltage
Traction Battery in
this section. CLEAR
the DTCs. REPEAT
the self-test. TEST
operation.
AE3 MEASURE BPSM TERMINATION RESISTANCE
Yes
WARNING: Always wear high-voltage insulated safety gloves GO to AE4 .
with leather outer gloves and a face shield when servicing the battery
pack sensor module (BPSM) and never remove the high-voltage No
BPSM connector unless directed by a service procedure. High voltage INSTALL a new
is present at the BPSM at all times, even with service disconnect plug BPSM . REFER to
removal . Depowering the system will not remove voltage from the Battery Pack Sensor
BPSM connector with the orange harness. Follow all service Module (BPSM) in
instructions. Failure to follow these instructions may result in serious this section. CLEAR
personal injury or death. the DTCs. REPEAT
the self-test. TEST
• Ignition OFF. the system for normal
• Measure the resistance between BPSM C4238B pin 22 and pin 23, operation.
component side.


AE4 MEASURE BECM TERMINATION RESISTANCE
Yes
• Measure the resistance between BECM C4237B pin 2 and pin 18, GO to AE5 .
component side.
No
INSTALL a new
BECM . REFER to
Battery Energy
Control Module
(BECM) in this
section. CLEAR the
DTCs. REPEAT the
self-test. TEST the
system for normal
operation.
AE5 RETEST AND ISOLATE MODULES
Yes
• Connect: BECM C4237B (leave BPSM C4238B disconnected). INSTALL a new
• Enter the following diagnostic mode on the scan tool: Clear DTCs - BECM . REFER to
BECM . Battery Energy
• Enter the following diagnostic mode on the scan tool: Self Test - BECM . Control Module
• Is DTC U0074:00 or U1006:00 retrieved? (BECM) in this
section. CLEAR the
DTCs. REPEAT the
self-test. TEST the
system for normal
operation.
No
INSTALL a new
BPSM . REFER to
Battery Pack Sensor
Module (BPSM) in
this section. CLEAR
the DTCs. REPEAT
the self-test. TEST
operation.
Pinpoint Test AF: DTCs U3001:00, U3003:16 and U3003:17

Normal Operation
During normal vehicle operation, the 12-volt battery supplies voltage to the Battery Energy Control Module
(BECM) in order for the BECM to operate. If this voltage is low or not available, the BECM cannot function
correctly.
• U3001:00 (Control Module Improper Shutdown: No Sub Type Information) - Fault sets if the BECM
loses its 12-volt power source unexpectedly and shuts down improperly. Reports as a continuous
memory (historical) DTC only.
• U3003:16 (Battery Voltage: Circuit Voltage Below Threshold) - Fault sets if the BECM 12-volt
power source falls below 8 volts for at least 5 seconds.
• U3003:17 (Battery Voltage: Circuit Voltage Above Threshold) - Fault sets if the BECM 12-volt
power source goes above 16 volts for at least 5 seconds.

• 12-volt battery
• Circuitry
• BECM
PINPOINT TEST AF: DTCs U3001:00, U3003:16 AND U3003:17

AF1 RETRIEVE ALL CMDTCs
Yes
• Connect the scan tool. REFER to Section 414-05 to diagnose the
• Ignition ON. DC/DC .
tool: Self Test - All CMDTCs . No
• Is DTC B1316, B1318, B1676, P0562, P0563, GO to AF2 .
U3001:00, U3003:16 or U3003:17 present in
more than 1 module?
AF2 CHECK 12-VOLT BATTERY
Yes
• Carry out the 12-volt battery condition test. GO to AF3 .
• Did the 12-volt battery pass the condition No
test? INSTALL a new battery. REFER to Section
414-01 for further information. CLEAR the
AF3 MEASURE DC/DC OUTPUT VOLTAGE
Yes
• Start the engine. GO to AF4 .
• For DTC U3003:17, turn off all accessories for a
minimum of 2 minutes. No
• For DTCs U3001:00 and U3001:16, turn on the CARRY OUT self-test of the DC/DC and
headlamps and HVAC fan for a minimum of 2 REFER to Section 414-05 to diagnose the

minutes. DC/DC .
• Measure 12-volt battery voltage.
• Is the voltage 13-15.2 volts?

AF4 COMPARE BATTERY VOLTAGE BECM
PID MAIN ECU VOLTAGE SUPPLY
(MAINBECMV)
Yes
• Enter the following diagnostic mode on the scan GO to AF7 .
tool: DataLogger - BECM .
• Monitor the BECM PID MAINBECMV. No
• Does the PID read 8-16 volts? If the PID reads less than 8 volts, GO to AF5 .
If the PID reads at least 16 volts, INSTALL a

new BECM . REFER to Battery Energy
Control Module (BECM) in this section.
CLEAR the DTCs. REPEAthe self-test. TEST
AF5 MEASURE BECM INPUT VOLTAGE
Yes
• Ignition OFF. GO to AF6 .
• Measure 12-volt battery voltage. No
VERIFY Battery Junction Box (BJB) fuse 47
(15A) is OK. If the fuse is OK, REPAIR the
circuit. If not OK, REFER to the Wiring
Diagrams manual to identify the possible
causes of the circuit short. CLEAR the DTCs.
normal operation.
• Measure the voltage between BECM

C4237A-47, SBB17 (RD), harness side and
ground and BECM C4237A-48, SBB17 (RD),
PINPOINT TEST AF: DTCs U3001:00, U3003:16 AND U3003:17 5588

• Are the BECM circuit voltages equal to

12-volt battery voltage?
AF6 CHECK BECM GROUND
Yes
• Measure the resistance between BECM GO to AF7 .
C4237A-49, GD126 (BK/WH), harness side and
ground; and BECM C4237A-50, GD126 No
(BK/WH), harness side and ground. REPAIR high resistance or open in the
affected circuit. CLEAR the DTCs. REPEAT
operation.

AF7 CHECK FOR CORRECT BECM
OPERATION
Yes
• Check the BECM harness and component side Energy Control Module (BECM) in this
connectors for: section. CLEAR the DTCs. REPEAT the
♦ corrosion. self-test. TEST the system for normal
♦ pushed-out/bent pins. operation.
• Connect the BECM and make sure the
connectors seat correctly. No
• Operate the system and determine if the concern The system is operating correctly at this time.
is still present. The concern may have been caused by a loose
• Is the concern still present? or corroded connector. CLEAR the DTCs.
normal operation.
Pinpoint Test AG: DTC U3003:62
Normal Operation
During normal vehicle operation the 12-volt battery supplies voltage to the Battery Energy Control Module
(BECM) in order for the BECM to operate. The BECM compares the voltage of the DC to DC Converter
Control Module (DC/DC) which is communicated via the High Speed Controller Area Network (HS-CAN).

• U3003:62 (Battery Voltage: Signal Compare Failure) - Fault sets wn the BECM does a compare with
the DC to DC Converter Control Module (DC/DC) and the input voltages to both modules do not
match.

• DC/DC
• BECM
PINPOINT TEST AG: DTCs U3003:62

AG1 RETRIEVE BECM DTCs
Yes
• Connect the scan tool. REFER to the Battery Energy Control Module (BECM) DTC
• Ignition ON. Chart and diagnose all other DTCs first.
mode on the scan tool: Self No
Test - BECM . GO to AG2 .
• Are any DTCs other than
U3003:62 retrieved?
AG2 RETRIEVE DC/DC DTCs
Yes
• Enter the following diagnostic REFER to Section 414-05 to diagnose DC/DC DTCs.
mode on the scan tool: Self
Test - DC/DC . No
• Are any DTCs retrieved? GO to AG3 .
AG3 CHECK FOR CORRECT
BECM OPERATION
Yes
• Ignition OFF. INSTALL a new BECM . REFER to Battery Energy Control
• Check the BECM harness and Module (BECM) in this section. CLEAR the DTCs. REPEAT
component side connectors for: the self-test. TEST the system for normal operation.
♦ corrosion.
• Connect the BECM and make The system is operating correctly at this time. The concern may
sure the connectors seat have been caused by a loose or corroded connector. CLEAR the
correctly. DTCs. REPEAT the self-test. TEST the system for normal
• Operate the system and operation.
determine if the concern is still
present.
Pinpoint Test AH: DTC P0AE0:00
PINPOINT TEST AG: DTCs U3003:62 5590

Normal Operation
these checks are normal, the BECM sends a signal to the contactor to close, which will supply high-voltage
power to the vehicle. If an overcurrent condition is sensed by the BECM , the stop safely hazard (red triangle)
warning indicator is illuminated and the vehicle will shut down and/or not start.
• P0AE0:00 (Hybrid Battery Negative Contactor Control Circuit High: No Sub Type Information) - If
the BECM detects overcurrent on the contactor control circuit for 16 milliseconds or more, this DTC
will be set. Reports as a continuous memory (historical) DTC only.

• Circuitry
• BECM /span>
• High-Voltage Bussed Electrical Center (BEC)
PINPOINT TEST AH: DTC P0AE0:00

AH1 CHECK FOR SHORT IN CIRCUIT
Yes
• Ignition OFF. GO to AH2 .
• Ignition ON. No
• Measure the voltage between BECM C4237B-55, circuit INSTALL a new HVTB (includes
J1-A55, harness side and ground; and between BECM HVTB system wire harness).
C4237B-56, circuit J1-A56, harness side and ground. REFER to High-Voltage Traction
Battery in this section. CLEAR
operation.

AH2 MEASURE CONTACTOR COIL RESISTANCE
Yes
GO to AH3 .

WARNING: Never install the service disconnect plug

when a high-voltage service cover is removed. Always No
install the cover prior to connecting the service disconnect INSTALL a new high-voltage
plug. The cover prevents inadvertent contact with the BEC . REFER to High-Voltage
high voltage which is present at several points under the Bussed Electrical Center in this
cover. Failure to follow these instructions may result in section. CLEAR the DTCs.
serious personal injury or death. REPEAT the self-test. TEST the
• Ignition OFF.
• With the service disconnect plug removed, measure the
resistance between high-voltage BEC C4236 pin 7 and pin 8,
component side.
AH3 CHECK FOR CORRECT BECM OPERATION
Yes
• Check the BECM harness and component side connectors to Battery Energy Control Module
for: (BECM) in this section. CLEAR
♦ corrosion. the DTCs. REPEAT the self-test.
• Connect the BECM and make sure the connectors seat No
correctly. The system is operating correctly
• Connect: High-voltage BEC C4236D. at this time. The concern may
• Install the high-voltage BEC cover. Refer to the exploded have been caused by a loose or
view in Battery Pack Sensor Module (BPSM) in this section. corroded connector. CLEAR the
• Connect: Service Disconnect Plug. DTCs. REPEAT the self-test.
• Operate the system and determine if the concern is still
present.
Pinpoint Test AI: DTC P0AE1:00
Normal Operation
power to the vehicle. If a precharge contactor overcurrent condition is sensed by the BECM , the stop safely
hazard (red triangle) warning indicator is illuminated and the vehicle will shut down and/or not start.
• DTC P0AE1:00 (High Voltage Battery Precharge Contactor Circuit: No Sub Type Information) -
Fault sets when the precharge contactor attempts to close and current flow exceeds set values. This
could indicate a short in the high-volta system. Reports as a continuous memory (historical) DTC
only.
PINPOINT TEST AH: DTC P0AE0:00 5592

• BECM
• Transmission Control Module (TCM)
PINPOINT TEST AI: DTC P0AE1:00

AI1 CHECK BECM DTCs
Yes
• Connect the scan tool. For DTC P0AA6:00, GO
• Ignition ON. to Pinpoint Test J .
BECM . No
• Is DTC P0AA6:00 retrieved? GO to AI2 .
AI2 RETRIEVE TCM DTCs
Yes
• Enter the following diagnostic mode on the scan tool: Self Test - REFER to the Powertrain
TCM . Control/Emissions
• Are any TCM DTCs retrieved? Diagnosis (PC/ED)
manual and diagnose
those DTCs first.
No
GO to AI3 .
AI3 CHECK CONTACTOR RESISTOR
Yes
WARNING: Never install the service disconnect plug when a GO to AI4 .
high-voltage service cover is removed. Always install t cover prior
inadvertent contact with the high voltage which is present at INSTALL a new
several points under the cover. Failure to follow these instructions high-voltage BEC .
may result in serious personal injury or death. REFER to High-Voltage
Bussed Electrical Center

• Ignition OFF. in this section. CLEAR

• Depower the HVTB system. Refer to High-Voltage Traction Battery the DTCs. REPEAT the
Systems Depowering in this section. self-test.
Refer to the exploded view in Battery Pack Sensor Module (BPSM)
in this section.
• With the service disconnect plug removed, measure the resistance of
the precharge resistor in the high-voltage BEC .

AI4 MEASURE VOLTAGE AT BPSM CONNECTOR
Yes
WARNING: Always wear high-voltage insulated safety gloves GO to AI7 .
with leather outer gloves and a face shield when servicing the
battery pack sensor module (BPSM) and never remove the No
high-voltage BPSM connector unless directed by a service GO to AI5 .
procedure. High voltage is present at the BPSM at all times, even
with service disconnect plug removal . Depowering the system
will not remove voltage from the BPSM connector with the
orange harness. Follow all service instructions. Failure to follow
these instructions may result in serious personal injury or death.

high-voltage service cover is removed. Always install the cover
prior to connecting the service disconnect plug. The cover
prevents inadvertent contact with the high voltage which is
present at several points under the cover. Failure to follow these
• Ignition ON.
• With the service disconnect plug removed, measure the voltage
between BPSM C4238B-35, circuit J2-B35, harness side and ground
by back-probing at C4238B-35.
PINPOINT TEST AI: DTC P0AE1:00 5594


AI5 CHECK CONTACTOR CIRCUIT FOR AN OPEN
Yes
• Ignition OFF. GO to AI6 .
• With the service disconnect plug removed, measure the resistance
between high-voltage BEC C4236E-D, circuit J2-B35, harness side No
and BPSM C4238B-35, circuit J2-B35, harness side. INSTALL a new HVTB
CLEAR the DTCs.
TEST the system for
normal operation.

AI6 CHECK FOR OPEN CONTACTOR
Yes
• With the service disconnect plug removed, measure the resistance INSTALL a new BPSM .
between the 2 points of the high-voltage BEC as shown. REFER to Battery Pack
Sensor Module (BPSM)
in this section. CLEAR
self-test. TEST the
system for normal
operation.
No
INSTALL a new
high-voltage BEC .
REFER to High-Voltage
Bussed Electrical Center
in this section. CLEAR
self-test. TEST the
system for normal
operation.
AI7 CHECK THE HIGH-VOLTAGE CABLES
Yes
• Install new high-voltage cables. Refer to High-Voltage Cables in this GO to AI8 .
section.
• Install the high-voltage BEC cover. Refer to the exploded view in No
Battery Pack Sensor Module (BPSM) in this section. Repair is complete.
PINPOINT TEST AI: DTC P0AE1:00 5595

• Ignition ON.
BECM .
BECM .
• Is DTC P0AE1:00 retrieved?
AI8 CHECK THE DC/DC
Yes
WARNING: Never install the service disconnect plug when a INSTALL a new ACCM
high-voltage service cover is removed. Always install the cover and A/C compressor
prior to connecting the service disconnect plug. The cover assembly. REFER to
prevents inadvertent contact with the high voltage which is Section 412-01 . CLEAR
present at several points under the cover. Failure to follow these the DTCs. REPEAT the
instructions may result in serious personal injury or death. self-test.
• Depower the HVTB system. Refer to High-Voltage Traction Battery Repair is complete.
• Ignition ON.
BECM .
BECM .
• Is DTC P0AE1:00 retrieved?
Pinpoint Test AJ: DTC P0AE5:00
Normal Operation
power to the vehicle. If the BECM senses the precharge contactor fails to close the stop safely hazard (red
triangle) warning indicator is illuminated and the vehicle will shut down and/or not start.
• P0AE5:00 (Hybrid Battery Precharge Contactor Control Circuit Range/Performance: No Sub Type
Information) - If the BECM signal to close the contactor fails, this DTC will be set. Reports as a
continuous memory (historical) DTC only.

• BECM

PINPOINT TEST AJ: DTC P0AE5:00

AJ1 CHECK CONTACTOR RESISTOR
Yes
WARNING: Never install the service disconnect plug GO to AJ2 .
plug. The cover prevents inadvertent contact with the high INSTALL a new high-voltage
voltage which is present at several points under the cover. BEC . REFER to High-Voltage
Failure to follow these instructions may result in serious Bussed Electrical Center in this
personal injury or death. section. CLEAR the DTCs.
resistance of the precharge resistor in the BEC .

AJ2 MEASURE CONTACTOR COIL RESISTANCE
Yes
• Disconnect: High-voltage BEC C4236D. GO to AJ3 .
resistance between high-voltage BEC C4236D pin 4 and pin No
5, component side. INSTALL a new high-voltage
PINPOINT TEST AJ: DTC P0AE5:00 5597

• Is the resistance between 5-50 ohms? BEC . REFER to High-Voltage

AJ3 CHECK FOR OPEN IN CIRCUIT
Yes
• Measure the resistance between high-voltage BEC C4236D, INSTALL a new BECM .
harness side and BECM C4237B, harness side as follows: REFER to Battery Energy
Control Module (BECM) in this
High-Voltage BEC Circuit BECM
C4236D-4 J1-A61 C4237B-61 No
INSTALL a new HVTB
C4236D-5 J1-A62 C4237B-62 (includes HVTB system wire
harness). REFER to
High-Voltage Traction Battery in
this section. CLEAR the DTCs.
Pinpoint Test AK: DTC P0AE7:00
Normal Operation
these checks are normal, the BECM sends a signal to the contactor to close, which will supply power to the
vehicle. If an overcurrent condition is sensed by the BECM , the stop safely hazard (red triangle) warning
indicator is illuminated and the vehicle will shut down and/or not start.
• P0AE7:00 (Hybrid Battery Precharge Contactor Control Circuit High: No Sub Type Information) - If
the BECM detects overcurrent on the contactor control circuit for 16 milliseconds or more, this DTC
will be set. Reports as a continuous memory (historical) DTC only.

• BECM
• Circuitry

PINPOINT TEST AK: DTC P0AE7:00
high-voltage cables and wiring are identified by orange harness tape or orange wire coveri. All

AK1 CHECK FOR SHORT IN CIRCUIT
Yes
• Measure the voltage between BECM C4237B-61, circuit INSTALL a new HVTB (includes
J1-A61, harness side and ground; and between BECM HVTB system wire harness).
C4237B-62, circuit J1-A62, harness side and ground. REFER to High-Voltage Traction
operation.
No
GO to AK2 .

AK2 MEASURE CONTACTOR COIL RESISTANCE
Yes
WARNING: Never install the service disconnect plug GO to AK3 .
plug. The cover prevents inadvertent contact with the INSTALL a new high-voltage
high voltage which is present at several points under the BEC . REFER to High-Voltage
cover. Failure to follow these instructions may result in Bussed Electrical Center in this
serious personal injury or death. section. CLEAR the DTCs.
• With the service disconnect removed, measure the resistance
between high-voltage BEC C4236D pin 4 and pin 5,
component side.
AK3 CHECK FOR CORRECT BECM OPERATION
Yes
PINPOINT TEST AK: DTC P0AE7:00 5599

♦ pushed-out/bent pins. TEST the system for normal

• Connect the BECM and make sure the connectors seat operation.
correctly.
• Connect: High-voltage BEC C4236D. No
• Install the high-voltage BEC cover. Refer to the exploded The system is operating correctly
view in Battery Pack Sensor Module (BPSM) in this section. at this time. The concern may
• Connect: Service Disconnect Plug. have been caused by a loose or
• Operate the system and determine if the concern is still corroded connector. CLEAR the
• Is the concern still present? TEST the system for normal
operation.
Pinpoint Test AL: DTC P0AFC:67
Normal Operation
During normal vehicle operation the Battery Energy Control Module (BECM) and Battery Pack Sensor
Module (BPSM) communicate with each other providing information each module needs to properly monitor
and control the high-voltage system. This communication is done over a dedicated Controller Area Network
(CAN). If the BECM senses a fault with leakage and/or contactor monitoring, BECM functions do not operate
correctly, the powertrain malfunction (wrench) warning indicator illuminates and the DTC is set.
• P0AFC:67 (Hybrid Battery Pack Sensor Module: Signal Incorrect After Event) - Fault sets if a BECM
leakage and/or contactor monitoring fault is present and BECM functions do not operate as
commanded.

• BECM
• BPSM
PINPOINT TEST AL: DTC P0AFC:67
high-voltage cables and wiring are identified by orange harness taper orange wire covering. All

Result / Action to
Test Step
Take
AL1 CHECK BPSM CIRCUITS FOR VOLTAGE
Yes
WARNING: Always wear high-voltage insulated safety gloves with GO to AL2 .
connector unless directed by a service procedure. High voltage is GO to AL8 .
present at the BPSM at all times, even with service disconnect plug
removal . Depowering the system will not remove voltage from the
BPSM connector with the orange harness. Follow all service
instructions. Failure to follow these instructions may result in serious

to connecting the service disconnect plug. The cover prevents
• Ignition OFF.
• Ignition ON.
BPSM C4238B-47, circuit J1-A66, harness side and ground; and between
BPSM C4238B-48, circuit J1-A65, harness side and ground.

AL2 CHECK BPSM GROUND CIRCUIT FOR OPEN
Yes
• Ignition OFF. GO to AL3 .
• With the service disconnect plug removed, measure the resistance between
BPSM C4238B-49, circuit J1-A70, harness side and ground. No
GO to AL8 .
PINPOINT TEST AL: DTC P0AFC:67 5601


AL3 CHECK DEDICATED CAN CIRCUITS
Yes
present at the BPSM at all times, even with service disconnect plug HVTB (includes
this section. CLEAR
• Disconnect: BECM C4237B. the DTCs. REPEAT
• With the service disconnect plug removed, measure the resistance between the self-test. TEST
BPSM C4238B, harness side and BECM C4237B, harness side as follows: the system for
normal operation.
BPSM Circuit BECM

C4238B-23 J1-A02 C4237B-2
C4238B-22 J1-A18 C4237B-18

AL4 CHECK CIRCUITS FOR SHORT TO GROUND
Yes
• With the service disconnect plug removed, measure the resistance between GO to AL5 .
BECM C4237B-2, circuit J1-A02, harness side and ground; and between
BECM C4237B-18, circuit J1-A18, harness side and ground. No
INSTALL a new
HVTB (includes
HVTB system wire
harness). REFER to
High-Voltage
Traction Battery in
this section. CLEAR
the DTCs. REPEAT

the self-test. TEST

the system for
normal operation.

AL5 MEASURE BPSM TERMINATION RESISTANCE
Yes
present at the BPSM at all times, even with service disconnect plug BPSM . REFER to
removal . Depowering the system will not remove voltage from the Battery Pack Sensor
BPSM connector with the orange harness. Follow all service Module (BPSM) in
instructions. Failure to follow these instructions may result in serious this section. CLEAR
personal injury or death. the DTCs. REPEAT
the self-test. TEST
• Measure the resistance between BPSM C4238B pin 22 and pin 23, the system for
component side. normal operation.

AL6 MEASURE BECM TERMINATION RESISTANCE
Yes
• Measure the resistance between BECM C4237B pin 2 and pin 18, GO to AL7 .
component side.
No
INSTALL a new
BECM . REFER to
Battery Energy
Control Module
(BECM) in this
section. CLEAR the
DTCs. REPEAT the
self-test. TEST the
system for normal
operation.
AL7 CHECK THE BPSM
Yes
connector unless directed by a service procedure. High voltage is Repair is complete.

present at the BPSM at all times, even with service disconnect plug TEST the system for
removal . Depowering the system will not remove voltage from the normal operation.
BPSM connector with the orange harness. Follow all service
instructions. Failure to follow these instructions may result in serious
• Install a new BPSM and the previously removed high-voltage BEC cover.
Refer to Battery Pack Sensor Module (BPSM) in this section.
• Connect: BECM C4237B.
• Ignition ON.
BECM .
• Enter the following diagnostic mode on the scan tool: Self Test - BECM .
• Is DTC P0AFC:67 ieved?
AL8 CHECK THE BECM
Yes
WARNING: Always wear high-voltage insulated safety gloves with INSTALL a new
leather outer gloves and a face shield when servicing the battery pack HVTB (includes HV
sensor module (BPSM) and never remove the high-voltage BPSM system wire
connector unless directed by a service procedure. High voltage is harness). REFER to
present at the BPSM at all times, even with service disconnect plug High-Voltage
removal . Depowering the system will not remove voltage from the Traction Battery in
BPSM connector with the orange harness. Follow all service this section. CLEAR
instructions. Failure to follow these instructions may result in serious the DTCs. REPEAT
personal injury or death. the self-test. TEST
the system for
• Ignition OFF. normal operation.
• Install a new BECM . Refer to Battery Energy Control Module (BECM) in
this section. No
• Connect: BPSM C4238B (if previously disconnected). Repair is complete.
• Install the high-voltage BEC cover (if previously removed). Refer to TEST the system for
Battery Pack Sensor Module (BPSM) in this section. normal operation.
• Connect: Service Disconnect Plug (if previously disconnected).
• Ignition ON.
BECM .
• Enter the following diagnostic mode on the scan tool: Self Test - BECM .
• Is DTC P0AFC:67 retrieved?
Pinpoint Test AM: DTC P0B1C:00
Normal Operation
The Battery Pack Sensor Module (BPSM) monitors battery pack voltage of the High Voltage Traction Battery
(HVTB). Normal pack voltage should be between 179-343 volts.
• P0B1C:00 (Hybrid Battery Pack Voltage Sense C Circuit High: No Sub Type Information) - Fault is
sewhen BPSM sensed higher than normal voltage.

• HVTB
• BPSM
PINPOINT TEST AM: DTC P0B1C:00

AM1 RETRIEVE BECM DTCs
Yes
WARNING: Never install the service disconnect plug REFER to the Battery Energy
when a high-voltage service cover is removed. Always Control Module (BECM) DTC
install the cover prior to connecting the service disconnect Chart and diagnose all other
plug. The cover prevents inadvertent contact with the high DTCs first.
Failure to follow these instructions may result in serious No
personal injury or death. GO to AM2 .
• Ignition OFF.
• Ignition ON.
DTCs - BECM .
- BECM .
• Are any DTCs other than P0B1C:00 retrieved?
AM2 CHECK THE BPSM
Yes
removal . Depowering the system will not remove voltage TEST the system for normal
PINPOINT TEST AM: DTC P0B1C:00 5605


Repair is complete. TEST the
• Ignition ON.
DTCs - BECM .
- BECM .
• Is DTC P0B1C:00 retrieved?
Pinpoint Test AN: DTC P0B36:00
Normal Operation
The service disconnect plug completes the high-voltage circuit. It has a non-serviceable fuse to protect the
high-voltage components in the event current raises above the normal operating range. The service disconnect
plug also shuts off the high-voltage to the system so service to the system can be completed safely. If the
service disconnect voltage becomes too high, the powertrain malfunction (wrench) warning indicator
illuminates and the DTC is set.
• P0B36:00 (High Voltage Service Disconnect Circuit High: No Sub Type Information) - This fault is
set when the service disconnect voltage is high for 1 second or more.

PINPOINT TEST AN: DTC P0B36:00
WARNING: Always inspect gloves before each use to prevent high-voltage shock. gh-voltage

AN1 RETRIEVE BECM DTCs

• Connect the scan tool. Yes

• Ignition ON. REFER to the Battery Energy
• Enter the following diagnostic mode on the scan tool: Clear Control Module (BECM) DTC
DTCs - BECM . Chart and diagnose all other
• Enter the following diagnostic mode on the scan tool: Self Test - DTCs first.
BECM .
• Are any DTCs other than P0B36:00 retrieved? No
GO to AN2 .
AN2 CHECK SERVICE DISCONNECT PLUG
Yes
WARNING: Never install the service disconnect plug INSTALL a new HVTB
when a high-voltage service cover is removed. Always install (includes HVTB system wire
the cover prior to connecting the service disconnect plug. harness). REFER to
The cover prevents inadvertent contact with the high voltage High-Voltage Traction Battery
which is present at several points under the cover. Failure to in this section. CLEAR the
follow these instructions may result in serious personal DTCs. REPEAT the self-test.
injury or death. TEST the system for normal
operation.
• Ignition OFF.
• Depower the HVTB system. Refer to High-Voltage Traction No
Battery Systems Depowering in this section. Repair is complete. TEST the
• Install a new BPSM . Refer to Battery Pack Sensor Module system for normal operation.
• Ignition ON.
DTCs - BECM .
BECM .
• Is DTC P0B36:00 retrieved?
Pinpoint Test AO: DTC P0B37:00
Normal Operation
The service disconnect plug completes the high-voltage circuit. It is fused to protect the high-voltage
components in the event current raises above the normal operating range. The service disconnect plug also
shuts off the high-voltage to the system so service to the system can be completed safely. When the service
disconnect plug is open, the stop safely hazard (red triangle) warning indicator is illuminated and the vehicle
will shut down and/or not start.
• P0B37:00 (High Voltage Service Disconnect Open: No Sup Type Information) - This DTC is set
when the service disconnect is open for 1 second or more while the service disconnect plug is still
inserted in the High Voltage Traction Battery (HVTB).

• HVTB
PINPOINT TEST AN: DTC P0B36:00 5607

PINPOINT TEST AO: DTC P0B37:00

AO1 CHECK SERVICE DISCONNECT PLUG POSITION
Yes
• Ignition OFF. GO to AO2 .
• Make sure service disconnect plug is inserted correctly and
securely. No
• Is the service disconnect plug seated correctly? REPOSITION service
disconnect plug correctly.
AO2 CHECK SERVICE DISCONNECT PLUG
Yes
WARNING: Never install the service disconnect plug GO to AO3 .
the cover prior to connecting the service disconnect plug. The No
cover prevents inadvertent contact with the high voltage INSTALL a new service
which is present at several points under the cover. Failure to disconnect plug. CLEAR the
follow these instructions may result in serious personal injury DTCs. REPEAT the self-test.
or death. TEST the system for normal
operation.
• Measure the resistance between the 2 service disconnect plug
terminals, component side.

AO3 CHECK THE BPSM
Yes
PINPOINT TEST AO: DTC P0B37:00 5608


servicing the battery pack sensor module (BPSM) and never harness). REFER to
remove the high-voltage BPSM connector unless directed by a High-Voltage Traction
service procedure. High voltage is present at the BPSM at all Battery in this section.
times, even with service disconnect plug removal . CLEAR the DTCs. REPEAT
Depowering the system will not remove voltage from the the self-test. TEST the system
BPSM connector with the orange harness. Follow all service for normal operation.
instructions. Failure to follow these instructions may result in
serious personal injury or death. No
WARNING: Never install the service disconnect plug system for normal operation.
the cover prior to connecting the service disconnect plug. The
cover prevents inadvertent contact with the high voltage
follow these instructions may result in serious personal injury
or death.

• Ignition ON.
• Enter the following diagnostic mode on the scan tool: Clear DTCs
- BECM . /li>
BECM .
• Is DTC P0B37:00 retrieved?
Pinpoint Test AP: P0BXX:00 Hybrid Battery Voltage Sense Circuit X Low/High
Normal Operation
The Battery Pack Sensor Module (BPSM) monitors battery pack voltage of the High Voltage Traction Battery
(HVTB). The BPSM also measures each of the 26 individual battery modules (identified as A through Z in
DTC descriptions) within the battery. The BPSM communicates normal pack voltage to the Battery Energy
Control Module (BECM) via a dedicated Controller Area Network (CAN).
NOTE: There are a total of 52 voltage sense circuit DTCs, 26 which indicate voltage circuit sense high and
26 which indicate voltage circuit sense low. The "X" in both the DTCs and DTC descriptions below will vary
using other letters and/or numbers (DTCs) or letters only (DTC description) depending on the actual DTC that
is present. Refer to the Battery Energy Control Module (BECM) DTC Chart in this section for the actual
listing of all 52 DTCs.
• P0BXX:00 (Hybrid Battery Voltage Sense Circuit X High: No Sub Type Information) - Fault is set
when BPSM monitors voltage in one individual battery module is more than 13.5 volts.
• P0BXX:00 (Hybrid Battery Voltage Sense Circuit X Low: No Sub Type Information) - Fault is set wh
BPSM monitors voltage in one individual battery module is less than 6.8 volts.


• BPSM
• HVTB
PINPOINT TEST AP: P0BXX:00 HYBRID BATTERY VOLTAGE SENSE CIRCUIT X LOW/HIGH

AP1 CHECK THE BPSM
Yes
removal . Depowering the system will not remove voltage TEST the system for normal
WARNING: Never install the service disconnect plug system for normal operation.
install the cover prior to connecting the service disconnect
plug. The cover prevents inadvertent contact with the high
Failure to follow these instructions may result in serious
• Ignition OFF.
• Ignition ON.
DTCs - BECM .
- BECM .
PINPOINT TEST AP: P0BXX:00 HYBRID BATTERY VOLTAGE SENSE CIRCUIT X LOW/HIGH
5610
• Is a Hybrid Battery Voltage Sense Circuit X High or

Hybrid Battery Voltage Sense Circuit X Low DTC
retrieved?
Pinpoint Test AQ: DTC P0A0C:00
Normal Operation
The Battery Energy Control Module (BECM) checks for continuity of the high-voltage system interlock
circuit. The interlock circuit must have continuity before high-voltage will be supplied to the vehicle. The
interlock circuit voltage travels through each of the high-voltage components and high-voltage cables and
back to the BECM . This fault will illuminate the stop safely hazard (red triangle) warning indicator and shut
down the vehicle.
• DTC P0A0C:00 (High Voltage System Interlock Circuit Low: No Sub Type Information) - Fault sets
when the BECM senses the interlock circuit is open or shorted to power for 5 seconds or more.

• BECM
• Transmission Control Module (TCM) (part of Electronically Controlled Continuously Variable
Transmissio(eCVT))
PINPOINT TEST AQ: DTC P0A0C:00

AQ1 CHECK FOR SHORT TO GROUND IN INTERLOCK
CIRCUIT
Yes
WARNING: Never install the service disconnect plug GO to AQ8 .
plug. The cover prevents inadvertent contact with the GO to AQ2 .
high voltage which is present at several points under the
cover. Failure to follow these instructions may result in

• Ignition OFF.
• Depower the High Voltage Traction Battery (HVTB) system.
Refer to High-Voltage Traction Battery Systems Depowering
in this section.
• Measure the resistance between BECM C4237B-44, circuit
J1-A44, harness side and ground; and between BECM
C4237B-47, circuit J1-A47, harness side and ground.

AQ2 CHECK FOR SHORT TO GROUND IN
HIGH-VOLTAGE CABLES IN INTERLOCK CIRCUIT
Yes
• Disconnect: High-voltage BEC C4236B. GO to AQ4 .
C4236B-1, circuit CYB04 (VT/BN), harness side and No
ground; and between high-voltage BEC C4236B-2, circuit GO to AQ3 .
CYB03 (BN/YE), harness side and ground.

CIRCUIT TO TCM
Yes
• Disconnect: TCM C1458C. INSTALL a eCVT . REFER to
• Measure the resistance between high-voltage BEC Section 307-01C . CLEAR the
C4236B-1, circuit CYB04 (VT/BN), harness side and DTCs. REPEAT the self-test.
ground; and between high-voltage BEC C4236B-2, circuit TEST the system for normal
CYB03 (BN/YE), harness side and ground. operation.
No
INSTALL new high-voltage
cables. REFER to High-Voltage
Cables in this section. CLEAR the
operation.
PINPOINT TEST AQ: DTC P0A0C:00 5612


CIRCUIT TO ACCM AND DC/DC
Yes
• Disconnect: High-voltage BEC C4236A. GO to AQ7 .
C4236A-3, circuit CYB02 (WH/BN), harness side and No
ground; and between high-voltage BEC C4236A-4, circuit GO to AQ5 .
CYB03 (BN/YE), harness side and ground.

CIRCUIT TO DC/DC
Yes
• Disconnect: DC/DC C1457A. INSTALL a new DC/DC .
• Measure the resistance between high-voltage BEC REFER to Section 414-05 .
C4236A-3, circuit CYB02 (WH/BN), harness side and CLEAR the DTCs. REPEAT the
ground; and between high-voltage BEC C4236A-4, circuit self-test. TEST the system for
CYB03 (BN/YE), harness side and ground. normal operation.
No
GO to AQ6 .

CIRCUIT TO ACCM
Yes
• Connect: DC/DC C1457A. INSTALL a new ACCM and A/C
• Disconnect: ACCM C1469B. compressor assembly. REFER to
• Measure the resistance between high-voltage BEC Section 412-01 . CLEAR the
C4236A-3, circuit CYB02 (WH/BN), harness side and DTCs. REPEAT the self-test.
ground; and between high-voltage BEC C4236A-4, circuit TEST the system for normal

CYB03 (BN/YE), harness side and ground. operation.
No
INSTALL new high-voltage
cables. REFER to High-Voltage
Cables in this section. CLEAR the
operation.

AQ7 CHECK FOR SHORT TO GROUND AT
HIGH-VOLTAGE BEC
Yes
• Remove the high-voltage BEC cover. Refer to the exploded INSTALL a new high-voltage
view in Battery Pack Sensor Module (BPSM) in this section. BEC . REFER to High-Voltage
• Disconnect: High-voltage BEC C4001. Bussed Electrical Center in this
• Disconnect: High-voltage BEC C4002. section. CLEAR the DTCs.
• Measure the resistance between high-voltage BEC C4001-1, REPEAT the self-test. TEST the
circuit J12-1, harness side and ground; and between system for normal operation.
high-voltage BEC C4001-3, circuit J1-A44, harness side and
ground. No
INSTALL a new HVTB (includes
HVTB system wire harness).
REFER to High-Voltage Traction
operation.
• Measure the resistance between high-voltage BEC C4002-1,

circuit J12-1, harness side and ground; and between
high-voltage BEC C4002-3, circuit J12-A47, harness side
and ground.

AQ8 CHECK FOR SHORT TO VOLTAGE IN INTERLOCK
CIRCUIT


• Measure the voltage between BECM C4237B-44, circuit GO to AQ9 .
J1-A44, harness side and ground; and between BECM
C4237B-47, circuit J1-A47, harness side and ground. No
GO to AQ15 .

AQ9 CHECK FOR VOLTAGE IN HIGH-VOLTAGE CABLES
IN INTERLOCK CIRCUIT
Yes
• Disconnect: High-voltage BEC C4236B. GO to AQ10 .
• Measure the voltage between high-voltage BEC C4236B-1,
circuit CYB04 (VT/BN), harness side and ground; and No
between high-voltage BEC C4236B-2, circuit CYB03 GO to AQ11 .
(BN/YE), harness side and ground.

AQ10 CHECK FOR VOLTAGE IN INTERLOCK CIRCUIT
TO TCM
Yes
• Disconnect: TCM C1458C. INSTALL new high-voltage
• Measure the voltage between high-voltage BEC C4236B-1, cables. REFER to High-Voltage
circuit CYB04 (VT/BN), harness side and ground; and Cables in this section. CLEAR the
between high-voltage BEC C4236B-2, circuit CYB03 DTCs. REPEAT the self-test.
(BN/YE), harness side and ground. TEST the system for normal
operation.
No
INSTALL a eCVT . REFER to
Section 307-01C . CLEAR the
operation.

TO ACCM AND DC/DC

• Disconnect: High-voltage BEC C4236A. Yes

• Measure the voltage between high-voltage BEC C4236A-3, GO to AQ12 .
circuit CYB02 (WH/BN), harness side and ground; and
between high-voltage BEC C4236A-4, circuit CYB03 No
(BN/YE), harness side and ground. GO to AQ14 .

TO DC/DC
Yes
• Disconnect: DC/DC C1457A. GO to AQ13 .
• Measure the voltage between high-voltage BEC C4236A-3,
circuit CYB02 (WH/BN), harness side and ground; and No
between high-voltage BEC C4236A-4, circuit CYB03 INSTALL a new DC/DC .
(BN/YE), harness side and ground. REFER to Section 414-05 .
normal operation.

TO ACCM
Yes
• Connect: DC/DC C1457A. INSTALL new high-voltage
• Disconnect: ACCM C1469B. cables. REFER to High-Voltage
• Measure the voltage between high-voltage BEC C4236A-3, Cables in this section. CLEAR the
circuit CYB02 (WH/BN), harness side and ground; and DTCs. REPEAT the self-test.
between high-voltage BEC C4236A-4, circuit CYB03 TEST the system for normal
(BN/YE), harness side and ground operation.
No
INSTALL a new ACCM and A/C
compressor assembly. REFER to
Section 412-01 . CLEAR the
operation.

AQ14 CHECK FOR VOLTAGE AT HIGH-VOLTAGE BEC

Yes
• Remove the high-voltage BEC cover. Refer to the exploded INSTALL a new HVTB (includes
view in Battery Pack Sensor Module (BPSM) in this section. HVTB system wire harness).
• Disconnect: High-voltage BEC C4001. REFER to High-Voltage Traction
• Disconnect: High-voltage BEC C4002. Battery in this section. CLEAR
• Measure the voltage between high-voltage BEC C4001-1, the DTCs. REPEAT the self-test.
circuit J12-1, harness side and ground; and between TEST the system for normal
high-voltage BEC C4001-3, circuit J1-A44, harness side and operation.
ground.
No
INSTALL a new high-voltage
BEC . REFER to High-Voltage
• Measure the voltage between high-voltage BEC C4002-1,

circuit J12-1, harness side and ground; and between
high-voltage BEC C4002-3, circuit J1-A47, harness side and
ground.

AQ15 CHECK FOR CORRECT BECM OPERATION
Yes
♦ pushed-out/bent pins. TEST the system for normal
• Connect: BECM C4237B . operation.
operation.


Rubber Insulating Gloves Testing
NOTE: The high-voltage insulated safety gloves must be recertified every 6 months to remain within OSHA
guidelines.
1. Leather gloves must always be worn over the rubber insulating gloves in order to protect them.
2. The gloves should not be used if they show any signs of wear and tear.
3. Roll the glove up from the open end until the lower portion of the glove begins to balloon from the
resulting air pressure. If the glove leaks any air, it must not be used.
4. Rubber insulating gloves must be class "00" and meet all of the American Society for Testing and
Materials standards.
Rubber Insulating Gloves Testing 5619

High-Voltage Traction Battery Systems Depowering
WARNING: Never install the service disconnect plug when a high-voltage service cover is removed.
Always install the cover prior to connecting the service disconnect plug. The cover prevents inadvertent
contact with the high voltage which is present at several points under the cover. Failure to follow these
1. Turn the ignition off.
2. Remove the 4 pin-type retainers and the trunk front cover.
3. NOTE: If the center safety belt retractor locks and the safety belt webbing prevents the 60 percent
backrest from lowering, raise the backrest upward to release the safety belt retractor and belt webbing.
Fold the LH backrest down.
• Between the High Voltage Traction Battery (HVTB) and the sheet metal, locate the seat
backrest latch release lever.
• Push the release lever toward the outboard side of the vehicle and fold the backrest down.
4. Slide the handle of the service disconnect plug toward the LH side of the vehicle.
High-Voltage Traction Battery Systems Depowering 5620

5. Rotate the handle upward.
6. Pull the service disconnect plug out and away from the HVTB . Be sure to store the plug in a place
where it cannot be accidentally re-installed while the vehicle is being serviced.
7. Wait 5 minutes after the service disconnect plug is removed before continuing service. This allows
any residual voltage in the high-voltage system to dissipate.
High-Voltage Traction Battery Systems Depowering 5621


1 10C665 High Voltage Traction Battery (HVTB)
cooling outlet duct
2 W712524 HVTB ground strap-to-chassis bolt
3 W505435 HVTB mounting bolts (8 required)
4 10A757 HVTB service disconnect plug
5 10B759 HVTB assembly
6 - Battery Energy Control Module
(BECM) 50-pin connector (part of
14A005)
7 - High-voltage/high-current electrical
8 - High-voltage/low-current electrical
9 19B680 HVTB cooling inlet duct plate
1. Depower the High Voltage Traction Battery (HVTB). For additional information, refer to
High-Voltage Traction Battery Systems Depowering in this section.
• Between the HVTB and the sheet metal, locate the seat backrest latch release lever.

3. Remove the RH rear seat bolster. For additional information, refer to Section 501-10 .
4. Disconnect the cooling fan jumper harness electrical connector, then remove the wiring connector
pushpin from the HVTB handle bracket.
5. Remove the HVTB cooling inlet duct. For additional information, refer to High-Voltage Traction
Battery Cooling Inlet Duct in this section.
6. Disconnect the 50-pin connector at the Battery Energy Control Module (BECM).
7. Remove the ground strap-to-chassis bolt and position the ground strap aside.
8. Remove the 2 plastic bumpers from the back of the rear seat back by releasing the 2 pushpins.
9. NOTE: The attaching bolts have a conductive coating on them and are serrated under the head flange.
These features ground the HVTB to the vehicle, which is required for electro-magnetic compatibility.
If a bolt(s) is lost or damaged, a new identical bolt(s) must be installed.
Remove the 4 HVTB mounting bolts from the trunk area that secure the HVTB to the brackets.
10. NOTE: The attaching bolts have a conductive coating on them and are serrated under the head flange.
These features ground the HVTB to the vehicle, which is required for electro-magnetic compatibility.
If a bolt(s) is lost or damaged, a new identical bolt(s) must be installed.
From each rear door opening, remove the 2 HVTB mounting bolts (total of 4 bolts) that secure the
HVTB to the brackets.
11. NOTICE: Lay a fender cover or other protective material over the seat backs to reduce the
possibility of damage when removing the battery.
NOTICE: Make certain the High Voltage Traction Battery (HVTB) does not mar or damage the
interior panels or seating during removal. There is very little clearance on each side.
With the help of an assistant inside the vehicle, grasp the handles on each side of the battery and slide
the battery forward and out of the vehicle.


High-Voltage Cables
Part
1 W713475 High-voltage cable shield nuts (7 required)
2 W704683 High-voltage cable strain relief bolt
3 - High-voltage cable strain relief clamp (part of 14300)
4 14300 High-voltage cable assembly
5 N807011 High-voltage cable shield screw
6 19B680 High Voltage Traction Battery (HVTB) cooling inlet
duct plate
7 - High-voltage cable floor pan grommet cover (part of
14300)
8 W713475 High-voltage cable floor pan grommet nuts (3 required)
High-Voltage Cables 5625

1. Discharge the A/C system. For additional information, refer to Section 412-00A .
2. Discot the 12-volt battery. For additional information, refer to Section 414-01 .
4. Fold the RH backrest down.


NOTE: DC to DC Converter Control Module (DC/DC) connector shown, high-voltage/low-current

connector at high-voltage Bussed Electrical Center (BEC) similar.
Release the locking lever and locking tabs and disconnect the interlock connector and the 2 high
voltage cables at the high-voltage BEC .
• Press the locking clip on the white interlock connector and disengage the white connector
7. Remove the HVTB cooling inlet duct plate.
8. Remove the pushpin that retains the high-voltage cables to the bracket on the HVTB case.
9. Remove the passenger side front seat. For additional information, refer to Section 501-10 .
10. Remove the front door scuff plate trim panel.

11. Remove the rear door scuff plate trim panel.
12. Remove the lower B-pillar trim panel.

• Slide the lower B-pillar trim panel down to disengage it from the upper B-pillar trim panel.
13. Remove the rear seat cushion. For additional information, refer to Section 501-10 .
14. Remove the high-voltage cable shield retaining screw.
15. Partially raise the LR seat back and pull the high-voltage cables out from under the rear seat backrest,
then position both rear seat backrests in the upright position.
16. NOTE: The high-voltage cables are routed under the passenger side rear carpet.
Disconnect the high-voltage cable from the DC/AC inverter and remove the 5 retaining clips. Position
the cable aside.
17. NOTICE: Make sure that the rear of the floor console is lifted away from the floor as specified.
Failure to follow this procedure will result in damage to the floor console and the tabs at the top
of the floor console end cover.
Remove the floor console end cover in the following sequence.
1. Remove the floor console rear screws.

2. Lift the floor console about 25 mm (0.984 in) away from the floor.
3. Remove the floor console end cover by pulling the cover away at the bottom and rotating out.
Lower the cover 7-13 mm (0.275-0.511 in) to clear the tabs on the top of the floor console
end cover.
18. Disconnect the AC power point connector.
19. Release the 2 pushpins that hold the high-voltage cables to the floor pan and pull the high-voltage
cable out from underneath the carpet and floor console.
20. Remove the 3 nuts at the floor pan grommet cover.
100-02 .

22. Remove the 5 nuts that retain the high-voltage cable shield to the floor pan and remove the cables
from the studs.
23. Remove the 2 nuts that retain the high-voltage cable shield to the bulkhead and remove the cables
from the studs.
24. Remove the pushpin that retains the high-voltage harness to the bulkhead.
25. Push the high-voltage cables through the opening of the vehicle floor pan.
26. Remove the engine cover.
27. Remove the high-voltage cable strain relief bolt and remove the strain relief clamp from the bracket.
28. Disconnect the high-voltage electrical connector from the transmission and position the cable aside.
29. Using a screwdriver or other suitable tool, release the clip that locks the high-voltage junction block
to the bracket by pushing the tool between the high-voltage junction block and the bracket from the
LH side. Remove the cable from the retainer on the bulkhead and position the cable aside.
30. Lift the high-voltage cables from the 2 studs on the front of the engine and disengage the pushpin at
the intake manifold.
NOTE: DC/DC connector shown, high-voltage/low-current connector at Air Conditioning

Compressor Module (ACCM) similar.
connector at the ACCM .
connector at the DC/DC .

33. Remove the A/C evaporator inlet fitting nut from the low side and disconnect the fitting nut. Discard
the gasket seal.
34. Remove the A/C compressor manifold and suction tube fitting nut (low side) and disconnect the
fitting. Remove the tube and discard the gasket seal.
35. Wrap mechanic's wire around the Hydraulic Control Unit (HCU) motor from above and support the
HCU .
36. Remove the 3 bolts that retain the HCU bracket to the frame.
37. An assistant is needed to help feed the cable down through the engine compartment and remove the
high-voltage cable assembly from the bottom of the vehicle.
38. To install, reverse removal procedure.

Battery Energy Control Module (BECM)
Special Tool(s)


1 W705790 Battery Energy Control Module (BECM) nuts (4
required)
2 - BECM connector (part of 14A005)
3 10B687 BECM
4 - BECM connector (part of 10B759)
1. Retrieve the module configuration. Carry out the module configuration retrieval steps of the
Programmable Module Installation (PMI) procedure. For additional information, refer to Section
418-01 .
Battery Energy Control Module (BECM) 5630

• Between the High Voltage Tractiattery (HVTB) and the sheet metal, locate the seat backrest
latch release lever.
4. Release the locking levers and disconnect the 2 electrical connectors at the Battery Energy Control
Module (BECM).
5. Remove the 4 nuts and the BECM .


• When installing a new BECM , carry out the steps necessary to complete Programmable
Module Installation (PMI). For additional information, refer to Section 418-01 .


Battery Pack Sensor Module (BPSM)
Part
1 W500010 High-voltage Bussed Electrical Center (BEC) cover
screw (2 required)
2 W705790 High-voltage BEC cover nuts (4 required)
3 10A687 High-voltage BEC cover
5 W705790 Battery Pack Sensor Module (BPSM) nut (4 required)
6 10B830 BPSM
7 - BPSM connectors (part of 10B759)
WARNING: Always wear high-voltage insulated safety gloves with leather outer gloves and a face
shield when servicing the battery pack sensor module (BPSM) and never remove the high-voltage
BPSM connector unless directed by a service procedure. High voltage is present at the BPSM at all
times, even with service disconnect plug removal . Depowering the system will not remove voltage from
the BPSM connector with the orange harness. Follow all service instructions. Failure to follow these
instructions may result in serious personal injuryr death.
Battery Pack Sensor Module (BPSM) 5633


3. Remove the 4 high-voltage Bussed Electrical Center (BEC) cover nuts, the 2 high-voltage BEC cover
screws and the high-voltage BEC cover.
4. Release the locking levers and disconnect the 2 connectors at the Battery Pack Sensor Module
(BPSM).
5. Remove the 4 nuts and the BPSM .



High-Voltage Bussed Electrical Center

1 W701596 High Voltage Traction Battery (HVTB) cable
nuts (2 required)
2 W705790 High-voltage Bussed Electrical Center (BEC)
nut
3 - HVTB B+ and B- cables (part of 10B759)
4 10C666 High-voltage BEC
5 10B759 HVTB
Always insta the cover prior to connecting the service disconnect plug. The cover prevents inadvertent

High-Voltage Bussed Electrical Center 5636

3. Remove the high-voltage cable connector and bracket. For additional information, refer to
High-Voltage Traction Battery Connector and Bracket in this section.
4. Release the locking tabs and disconnect the 3 connectors.
5. Remove the 2 HVTB cable nuts and detach the cables from the high-voltage Bussed Electrical Center
(BEC).
6. Remove the nut at the upper LH corner and remove the high-voltage BEC .


High-Voltage Traction Battery Connector and Bracket

1 W505530 High-voltage Bussed Electrical Center
(BEC) cover screws (2 required)
2 W705790 High-voltage BEC cover nuts (4
required)
4 10A757 High Voltage Traction Battery
(HVTB) service disconnect plug
5 14300 High-voltage cable
6 14E049 High-voltage cable connector and
bracket assembly
7 W705790 High-voltage cable connector and
bracket assembly nuts (3 required)
8 W506973 High-voltage cable connector and
bracket assembly screw
9 W702841 High-voltage/low-current positive
cable nut
10 W701596 High-voltage/high-current and
low-current negative cable nut
High-Voltage Traction Battery Connector and Bracket 5639

11 W701596 High-voltage/high-current positive

cable nut
12 10C666 High-voltage BEC


NOTE: DC to DC Converter Control Module (DC/DC) connector shown, high-voltage/low-current

connector at HVTB similar.
Release the locking lever and locking tabs and disconnect the interlock connector and the 2
high-voltage cables.

4. Remove the 4 nuts and 2 screws at the HVTB Bussed Electrical Center (BEC) cover and remove the
cover.
5. Disconnect the 2 interlock circuit connectors on the high-voltage cable connector and bracket.
6. Remove the high-voltage/high-current positive cable nut.

7. Remove the high-voltage/high and low-current negative cable nut.

8. Remove the high-voltage/low-current positive cable nut at the 40A fuse.

9. Remove the 3 nuts, 1 bolt and the high-voltage cable connector and bracket assembly.
• To install, tighten the 3 nuts to 9 Nm (80 lb-in).
• To install, tighten the bolt to 6 Nm (53 lb-in).

High-Voltage Low-Current Fuse

1 W505530 High-voltage Bussed Electrical Center
(BEC) cover screws (2 required)
2 W705790 High-voltage BEC cover nuts (4
required)
4 10A757 High Voltage Traction Battery
(HVTB) service disconnect plug
5 14300 High-voltage cable
6 14E049 High-voltage cable connector and
bracket assembly
7 W702841 High-voltage/low-current fuse nuts (2
required)
8 W701596 High-voltage/high-current positive
cable nut
9 - High-voltage/low-current circuit bus
bar (part of 10C666)
10 - High-voltage/high-current positive
cable (part of 14E049)
High-Voltage Low-Current Fuse 5642

11 14526 High-voltage/low-current fuse (40A)

1. Depower the High Voltage Traction Battery (HVTB). For additional informn, refer to High-Voltage

3. Remove the 4 nuts, 2 bolts and the high-voltage BEC cover.

4. Remove the high-voltage/high-current fuse.

1. Remove the high-voltage/high-current positive cable nut.
♦ To install, tighten to 15 Nm (133 lb-in).
2. Position the high-voltage/high-current positive cable aside.
3. Remove the 2 high-voltage/low-current fuse nuts on each end of the fuse.
4. Remove the high-voltage/low-current circuit bus bar.
5. Remove the high-voltage/low-current fuse (40A).


High-Voltage Traction Battery Inlet Air Temperature Sensor
Part
1 - High Voltage Traction Battery (HVTB) inlet air
temperature sensor connector (part of 10B759)
2 14A606 HVTB inlet air temperature sensor
3 10B768 HVTB inlet air duct
High-Voltage Traction Battery Inlet Air Temperature Sensor 5645

3. Release the locking tab and removthe connector from the HVTB inlet air temperature sensor.
4. Remove the HVTB inlet air temperature sensor.

• Turn the sensor counterclockwise to unlock and release it from the plenum.
High-Voltage Traction Battery Inlet Air Temperature Sensor 5646

High-Voltage Traction Battery Cooling Outlet Duct
Part
1 W713475 High Voltage Traction Battery (HVTB) cooling outlet
duct nuts (3 required)
2 W708703 HVTB cooling outlet duct screws (6 required)
3 14D641 HVTB cooling fan jumper wiring harness
4 10C665 HVTB cooling outlet duct
5 - HVTB cooling fan connector (part of 14A005)
1. Remove the High Voltage Traction Battery (HVTB) cooling fan. For additional information, refer to
High-Voltage Traction Battery Cooling Fan in this section.
• Push the release lever toward the outboard side of the vehicle and fold the backrest down
High-Voltage Traction Battery Cooling Outlet Duct 5647

3. Release the locking tab and disconnect the HVTB cooling fan jumper harness. Rove the clips holding
the harness to the HVTB mounting bracket and HVTB case.
4. Release the clips that hold the HVTB cooling fan jumper harness to the HVTB cooling outlet duct and
remove the harness from the duct.
5. Remove the 6 bolts and 3 nuts and remove the HVTB cooling outlet duct.
High-Voltage Traction Battery Cooling Outlet Duct 5648

High-Voltage Traction Battery Cooling Inlet Duct
Material
Item Specification
TA-25
Part
1 19B680 High Voltage Traction Battery (HVTB) cooling inlet
duct plate
3 W705790 HVTB cooling inlet duct nuts (4 required)
4 10B768 HVTB cooling inlet duct

High-Voltage Traction Battery Cooling Inlet Duct 5649

3. Pull loose and remove the cooling inlet duct plate in front of the high-voltage cables.

Disconnect the high-voltage/high-current, high-voltage/low-current and interlock connectors.
before releasing the locking clip on the orange portion of the high-voltage/low-current
connector. The white interlock connector will not come completely apart until the orange
portion is released.
5. Remove the 4 HVTB cooling inlet duct nuts and the inlet duct.
• To install, apply a small amount of threadlock and sealer and tighten to 6 Nm (53 lb-in).


High-Voltage Traction Battery Cooling Fan
Material
Item Specification
Instant Gel Adhesive WSK-M2G402-A4
TA-19
Part
1 W790165 High Voltage Traction Battery (HVTB) cooling fan
screw (4 required)
2 10C659 HVTB cooling fan
3 14D641 HVTB cooling fan jumper harness
4 10C665 HVTB outlet air duct
1. Open the trunk, remove the 4 pin-type retainers and the front trunk cover.
2. Release the locking tab and separate the High Voltage Traction Battery (HVTB) cooling fan
connector.
3. Remove the 4 HVTB cooling fan screws.
4. Remove the HVTB cooling fan.
High-Voltage Traction Battery Cooling Fan 5652

5. To install, add a small amount of instant gel adhesive to the HVTB cooling fan screws and reverse the
removal procedure.

SECTION 414-05: High Voltage 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid
Converter/Inverter Workshop Manual
Item Specification
DC to DC Converter Control Module (DC/DC) voltage output 13.3-14.7 volts
DC/DC output current capacity 100-145 amps

A/C tube bracket bolt 6 - 53
DC/AC inverter nuts 9 - 80
DC to DC Converter Control Module (DC/DC) low-voltage battery cable nuts 17 - 150
DC/DC lower LH bracket bolts 5 - 44
DC/DC lower RH bracket nut 22 16 -
DC/DC top bracket bolts 9 - 80

High-Voltage Converter/Inverter
DC to DC Converter Control Module (DC/DC)
service instructions, including instructions to depower the system. The high-voltage hybrid system
utilizes approximately 300 volts DC, provided through high-voltage cables to its components and
modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire
covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage
symbol. Failure to follow these instructions may result in serious personal injury or death.
The DC to DC Converter Control Module (DC/DC) is a liquid-cooled component that converts high-voltage
(179-343 volts) DC power from the High Voltage Traction Battery (HVTB) to low-voltage (12 volts) DC
power. This charges the 12-volt battery through the low-voltage battery cables and powers the low-voltage
electrical systems, eliminating the need for a conventional engine-driven generator. It utilizes a dedicated
control module, which is part of the DC/DC . The DC/DC communicates with other modules over the High
Speed Controller Area Network (HS-CAN) bus, and is located on the RH frame rail, behind the radiator
support.
High-Voltage Cable Assembly
All cables that carry high voltage are integrated into a single high-voltage cable assembly that runs between
the DC/DC , the Electronically Controlled Continuously Variable Transmission (eCVT), the Air Conditioning
Compressor Module (ACCM) and the HVTB . The high-voltage cable assembly can be serviced separately
from the rest of the high-voltage system.
DC/AC Inverter and AC Power Point
The DC/AC inverter converts low voltage (12 volts) DC to 110 volts AC to power a device that uses AC
power with a rating of less than 150 watts. The DC/AC inverter is located behind the RH rear seat bolster, and
is a serviceable part. The AC power point is located in the rear of the floor console and can be serviced
separately from the floor console.
High-Voltage Converter/Inverter 5655


High-Voltage Converter/Inverter
Special Tool(s)
Flex Probe Kit



Principles of Operation - DC to DC Converter Control Module (DC/DC)
The DC to DC Converter Control Module (DC/DC) is a liquid-cooled component that converts high voltage
(179-343 volts) DC power to low voltage (12 volts) DC power, while maintaining electrical isolation between
the 2 systems. The DC/DC is enabled when the High Voltage Traction Battery (HVTB) contactors have
closed, providing high-voltage power to the DC/DC (for information on the HVTB system, refer to Section
414-03 ). The DC/DC steps the high voltage down to a low-voltage (between 12 and 15 volts, depending on
vehicle needs), providing power to the vehicle low-voltage battery systems. The DC/DC also charges the
12-volt battery through the low-voltage battery cables as necessary, eliminating the need for a conventional
engine-driven generator. Depending on vehicle and environmental conditions, the DC/DC is capable of
outputting as many as 145 amps to the 12-volt battery.
The DC/DC is liquid-cooled and is part of the Motor Electronics Cooling System (MECS). In addition to the
DC/DC , the MECS also provides cooling of the Electronically Controlled Continuously Variable
Transmission (eCVT). For information on the MECS , refer to Section 307-02B .
The DC/DC communicates on the High Speed Controller Area Network (HS-CAN). When a fault is sensed by
the DC/DC , a DTC is set and can be retrieved using a scan tool connected to the Data Link Connector (DLC).
The PCM communicates charging needs of the 12-volt system to the DC/DC over the HS-CAN , enabling the
DC/DC to control low-voltage charging operations.
The DC/DC receives the following HS-CAN messages:
• Transmission Control Module (TCM) high-voltage input, via the TCM

• Ignition status, via the Instrument Panel Cluster (IPC)
• MECS coolant temperature, via the PCM
• "Ready Indicator Light" illumination request, via the PCM
• Transaxle gear mode, via the PCM
• DC/DC enable and low-voltage set point request, via the PCM
Faults with the DC/DC system that cause low or excessively high 12-volt battery voltage will result in the
DC/DC sending a HS-CAN message to the IPC requesting the CHECK CHARGING SYSTEM message be

displayed in the message center.
Principles of Operation - High-Voltage Cable Assembly
The high-voltage cable assembly contains 4 basic circuits:
• The high-voltage/high-amperage cables run between the HVTB and the eCVT .
• The high-voltage/low-amperage cables run from the HVTB to the DC/DC and the Air Conditioning
Compressor Module (ACCM).
• The interlock circuit consists of small-gauge wiring wrapped around the high-voltage cables. It is a
continuous, single circuit used to monitor the integrity of the high-voltage connections. The interlock
connectors are part of the high-voltage cable connectors and are either disconnected at the same time
as the high-voltage cable, or must be disconnecd before the high-voltage cable depending upon the
type of connection being serviced.
• The AC power point high-voltage wiring and LED indicator circuits between the DC/AC inverter and
the AC power point.
All high-voltage wiring utilizes orange insulation as well as orange tape and/or harness tubing.
Principles of Operation - DC/AC Inverter and AC Power Point
The DC/AC inverter converts 12 volts DC to 110 volts AC to power a device that uses AC electricity with a
rating of less than 150 watts. The 110 volts AC created by the inverter will measure differently than a
conventional AC outlet (utility-generated) with some multi-meters. The AC power point will automatically
shut off if the load exceeds 150 watts, to help prevent damage to the inverter or load. The inverter supplies
110 volts AC power only when the ignition is in the ON/START position. This reduces the draw on the
12-volt system when the vehicle is not running. The AC power point is equipped with a green LED that
indicates the system integrity.
• Green LED illuminates continuously - ignition in ON/START and system is operating normally.
• Green LED flashes continuously - ignition in ON/START and a fault is detected.
• Green LED does not illuminate - ignition is not in ON/START, fault on the RUN/START circuit
input to the DC/AC inverter or the DC/AC inverter is not powered (fault with DC/AC inverter B+ or
ground circuits).
Short circuits, overloads or overheating of the inverter will cause the green LED to flash and the power to be
cut off to the outlet. If the LED is flashing, the problem must be corrected (short circuit or excessive load). If
the DC/AC inverter is overheated, it must be allowed time to cool off (without the load connected). Refer to
the Owner's Literature for a list of appropriate electrical loads/devices that can be used.
nspection and Verification - DC to DC Converter Control Module (DC/DC) System

Electrical
• Battery Junction Box (BJB) fuse 47 (10A)

• B+ cable fuse (200A)
• B+ terminal at DC to DC Converter Control Module (DC/DC) converter control
module
• 12-volt battery
• DC/DC
NOTE: Make sure to use the latest scan tool software release.
If the cause is not visually evident, connect the scan tool to the DLC .
5. NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground to
the VCM .

• refer to Section 418-00 , No Power to the Scan Tool, to diagnose no power to the scan tool.

7. Carry out the Network Test.

• If the scan tool responds with no communication with one or more modules, refer to Section
418-00 .
• If the Network Test passes, retrieve and record the continuous memory DTCs.
8. Clear the continuous memory DTCs and carry out the self-test diagnostics for the DC/DC and PCM.
9. If the DTCs retrieved are related to this concern, go to the DC to DC Converter Control Module
(DC/DC) DTC Chart or the PCM DTC Chart.
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - DC/DC Converter Control
Module (DC/DC) System .

Inspection and Verification - DC/AC Inverter System
Electrical

fuse(s):
♦ 4 (30A)
♦ 35 (10A)
connectors
• AC power point
• DC/AC inverter
4. If the cause is not visually evident, verify the symptom and GO to Symptom Chart - DC/AC Inverter
System .
DTC Charts
DC to DC Converter Control Module (DC/DC) DTC Chart

P0A12:16 DC/DC Converter GO to Pinpoint Test A .
Enable Circuit Low:
Circuit Voltage Below
Threshold

P0A94:4B DC/DC Converter GO to Pinpoint Test B .

Performance: Over
Temperature
P0AF7:00 14 Volt Power Module GO to Pinpoint Test C .
Internal Temperature
Too High: No Sub Type
Information
P0AFA:13 Hybrid Battery System GO to Pinpoint Test D .
Open
P0AFA:16 Hybrid Battery System GO to Pinpoint Test E .
Voltage Below
Threshold
P0AFB:17 Hybrid Battery System GO to Pinpoint Test F .
Voltage High: Circuit
Voltage Above
Threshold
U0001:88 High Speed Controller The DC to DC Converter Control Module (DC/DC) could not
Area Network communicate on the network at a point in time. The fault is currently
(HS-CAN) not present. CLEAR the DTC. REPEAT the Network Test with the
Communication Bus: scan tool. REFER to Section 418-00 for further diagnosis as needed.
Bus Off
U0100:00 Lost Communication REFER to Section 418-00 to diagnose lost PCM communication.
With ECM/PCM "A":
No Sub Type
Information
U0101:00 Lost Communication REFER to Section 418-00 to diagnose lost Transmission Control
With TCM : No Sub Module (TCM) communication.
Type Information
U0155:00 Lost Communication REFER to Section 418-00 to diagnose lost IPC module communication.
With Instrument Panel
Cluster (IPC) Control
Module: No Sub Type
Information
U0300:00 Internal Control Module DIAGNOSE any other DC/DC DTCs first. If no other DC/DC DTCs
Software are present, GO to Pinpoint Test G .
Incompatibility: No Sub
Type Information
U0401:68 Invalid Data Received NOTE: DTC U0401:68 indicates a HS-CAN message from the PCM is
From ECM/PCM A: outside normal limits due to a faulty PCM input.
Event Information
REVIEW freeze frame data for DTC U0401:68 to determine if the fault
pertains to the Motor Electronics Cooling System (MECS) coolant
temperature sensor, ambient air temperature or vehicle voltage.
RETRIEVE PCM DTCs and DIAGNOSE any DTCs related to MECS
coolant temperature sensor, ambient air temperature or vehicle voltage.
REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual
for further diagnosis.
U0402:68 Invalid Data Received NOTE: DTC U0402:68 indicates a HS-CAN message from the TCM is
From TCM : Event outside normal limits due to a faulty TCM input.
Information

RETRIEVE TCM DTCs and DIAGNOSE any DTCs related to

high-voltage input. REFER to Powertrain Control/Emissions Diagnosis
(PC/ED) manual for further diagnosis.
U3000:04 Control Module: System CLEAR the DTC. REPEAT the self-test. If the DTC is still present,
Internal Failure INSTALL a new DC/DC .
U3000:41 Control Module: General DIAGNOSE any other DC/DC DTCs first. If no other DTCs are
Checksum Failure present, CLEAR the DTC. REPEAT the self-test. If the DTC is still
present, INSTALL a new DC/DC . REFER to Direct Current/Direct
Current (DC/DC) Converter in this section.
U3000:42 Control Module: General DIAGNOSE any other DC/DC DTCs first. If no other DTCs are
Memory Failure present, CLEAR the DTC. REPEAT the self-test. If the DTC is still
present, INSTALL a new DC/DC . REFER to Direct Current/Direct
U3000:45 Control Module: DIAGNOSE any other DC/DC DTCs first. If no other DTCs are
Program Memory present, CLEAR the DTC. REPEAT the self-test. If the DTC is still
Failure present, INSTALL a new DC/DC . REFER to Direct Current/Direct
U3000:49 Control Module: Internal If the 12V battery is on a charger, REMOVE the charger. CLEAR the
Electronic Failure DTC. REPEAT the self-test. If DTC U3003:49 returns, INSTALL a
new DC/DC . REFER to Direct Current/Direct Current (DC/DC)
Converter in this section.
U3000:96 Control Module: CLEAR the DTC. REPEAT the self-test. REFER to Direct
Component Internal Current/Direct Current (DC/DC) Converter in this section. If the DTC
Failure is still present, INSTALL a new DC/DC .
Voltage Below
Threshold
U3003:17 Battery Voltage: Circuit GO to Pinpoint Test I .
Voltage Above
Threshold
U3003:62 Battery Voltage: Signal GO to Pinpoint Test J .
Compare Failure
PCM DTC Chart

P0562 System Voltage Low GO to Pinpoint Test H .
P0563 System Voltage High GO to Pinpoint Test I .
Symptom Chart - DC to DC Converter Control Module (DC/DC) System
Symptom Chart - DC to DC Converter Control Module (DC/DC) System


• CHECK CHARGING SYSTEM displayed in the message center
• Fuse(s)
• 12-volt battery
• DC/DC
• CARRY OUT self-test of the DC/DC and REFER to the DC to DC Converter Control Module
(DC/DC) DTC Chart for further diagnosis.
Symptom Chart - DC/AC Inverter System
Symptom Chart - DC/AC Inverter System
Pinpoint Tests
Pinpoint Test A: DTC P0A12:16
Normal Operation
The DC to DC Converter Control Module (DC/DC) monitors the PCM relay control circuit voltage. If the
PCM relay control circuit to the DC/DC becomes open or voltage is low, DTC P0A12:16 sets and the DC/DC
maintains standard operation of the charging system, though a delay in vehicle start-up time may occur.
• DTC P1A12:16 (DC/DC Converter Enable Circuit Low: Circuit Voltage Below Threshold) - Sets
when the PCM relay control circuit provides less than 7 volts to DC/DC C1457D-7.

• Fuse
• DC/DC
PINPOINT TEST A: DTC P0A12:16

A1 CHECK THE BATTERY POSITIVE

CIRCUIT VOLTAGE
Yes
• Measure the voltage between DC/DC
C1457B, B+ terminal and ground. No
GO to A2 .
• START the vehicle (Ready Indicator light

ON).
• Measure the voltage between DC/DC
C1457B, B+ terminal and ground.
• Did the voltage increase with the

ignition ON?
A2 CHECK THE DC TO DC VOLTAGE
CONVERTER STATUS (EnableStat) PID
Yes
• Connect the scan tool. GO to A4 .
the scan tool: DataLogger - DC/DC . No
• Monitor the EnableStat PID. CARRY OUT self-test of the PCM and Battery
• Does the PID read Enable? Energy Control Module (BECM). REFER to
manual and Section 414-03 for further diagnosis.
A3 CHECK THE PCM RELAY CONTROL
INPUT TO THE DC/DC
Yes
• Disconnect: DC/DC C1457D.
• START the vehicle (Ready Indicator light No
ON). VERIFY the Battery Junction Box (BJB) fuse 47
• Measure the voltage between DC/DC (10A) is OK. If OK, REPAIR circuit CBK03 (GY). If
C1457D-7, circuit CBK03 (GY), harness not OK, REFER to the Wiring Diagrams manual to
side and ground. identify the possible causes of the circuit short.
CLEAR the DTC. REPEAT the self-test. TEST the
PINPOINT TEST A: DTC P0A12:16 5664


A4 CLEAR DTCs AND CARRY OUT
SELF-TEST OF THE DC/DC
Yes
• Using the scan tool, clear the DC/DC INSTALL a new DC/DC . REFER to Direct
DTCs. Current/Direct Current (DC/DC) Converter in this
• Wait a minimum of 65 seconds before section. REPEAT the self-test. TEST the system for
carrying out the next step. normal operation.
the scan tool: Self Test - DC/DC . No
• Is DTC P0A12:16 reported? Concern is not present at this time. INSPECT the
PCM relay control input to DC/DC C1457D-7,
circuit CBK03 (GY) for intermittent faults. CLEAR
the DTC. REPEAT the self-test. TEST the system for
normal operation.
Pinpoint Test B: DTC P0A94:4B
Normal Operation
The DC to DC Converter Control Module (DC/DC) provides power for the low-voltage vehicle systems and
charging of the 12-volt battery. The DC/DC can receive a High Speed Controller Area Network (HS-CAN)
message from the PCM indicating that the Motor Electronics Cooling System (MECS) temperature exceeds
80°C (176°F). Because of this, the DC/DC may limit current output to 100 amps (maximum output is
normally greater than 100 amps). When either condition is present, DTC P0A94:4B sets and the DC/DC will
continue limiting current until the over-temperature condition clears. Periodic or constant heavy electrical
loads of the 12-volt system may cause the 12-volt battery to become drained. Reduced functionality of 12-volt
systems (headlamps, HVAC blower motor, etc.) may also be noticed.
• DTC P0A94:4B ( DC/DC Performance: Over Temperature) - Sets when the MECS temperature
exceeds 80°C (176°F) and/or the DC/DC is limiting current output to 100 amps.

• MECS
• DC/DC

PINPOINT TEST B: DTC P0A94:4B
• Connect
the scan
tool.
• Ignition Yes
ON. REFER to Section 307-02B
• Enter the to inspect and diagnose the
following MECS cooling loop circuit.
B1 CARRY OUT
diagnostic CLEAR the DTC. REPEAT
SELF-TEST OF
mode on the self-test. TEST the
THE PCM
the scan system for normal operation.
tool: Self
Test - No
PCM. GO to B2 .
• Is PCM
DTC
P0A7C:00
reported?
B2 CHECK FOR
DC/DC DTC
P0AF7:00
Yes
• Enter the GO to Pinpoint Test C .
following
diagnostic No
mode on the GO to B3 .
scan tool:
Self Test -
DC/DC .
• Is DTC
P0AF7:00
reported?
B3 CLEAR DTCs
AND CARRY OUT
SELF-TEST OF
THE DC/DC
Yes
• Using the INSTALL a new DC/DC .
scan tool, REPEAT the self-test. TEST
clear the the system for normal
DC/DC operation.
DTCs.
• Enter the No
following Concern is not present at this
diagnostic time. CHECK the MECS
mode on the coolant level. REFER to
scan tool: Section 307-02B . CLEAR the
Self Test - DTC. REPEAT the self-test.
DC/DC . TEST the system for normal
operation.
PINPOINT TEST B: DTC P0A94:4B 5666

• Is DTC
P0A94:4B
reported?
Pinpoint Test C: DTC P0AF7:00
Normal Operation
The DC to DC Converter Control Module (DC/DC) is cooled by the Motor Electronics Cooling System
(MECS). The DC/DC monitors its temperature internally. If the internal temperature becomes excessive, DTC
P0AF7:00 sets and the DC/DC will be in standby mode ( DC/DC disabled) until the over-temperature
condition clears. Presence of this DTC will result in CHECK CHARGING SYSTEM being displayed in the
message center and the 12-volt battery eventually becoming drained. Reduced or no functionality of 12-volt
systems (headlamps, HVAC blower motor, etc.) may also be noticed.
• DTC P0AF7:00 14 (Volt Power Module Internal Temperature Too High: No Sub Type Information) -
Sets when the DC/DC senses high internal temperature.

• MECS
• DC/DC
PINPOINT TEST C: DTC P0AF7:00

C1 CHECK FOR DC/DC DTC P0A94:4B
Yes
• Connect the scan tool. REFER to Section 307-02B to inspect and diagnose
• Ignition ON. the MECS cooling loop circuit.
the scan tool: Self Test - DC/DC . No
• Is DTC P0A94:4B reported? GO to C2 .
C2 CLEAR DTCs AND CARRY OUT
SELF-TEST OF THE DC/DC
Yes
• Using the scan tool, clear the DC/DC INSTALL a new DC/DC . CLEAR the DTC.
• Enter the following diagnostic mode on operation.
the scan tool: Self Test - DC/DC .
• Is DTC P0AF7:00 reported? No
Concern is not present at this time. REPEAT the
Pinpoint Test D: DTC P0AFA:13

Normal Operation
The DC to DC Converter Control Module (DC/DC) monitors the high voltage available from the High
Voltage Traction Battery (HVTB). The DC/DC compares that high-voltage reading with the high voltage
available to the Transmission Control Module (TCM), which is communicated via a High Speed Controller
Area Network (HS-CAN) message. When the DC/DC compares its available high voltage to that available to
the TCM and determines the difference to be 150 volts or more, it will set DTC P0AFA:13 and request the
CHECK CHARGING SYSTEM message be displayed in the message center. The DC/DC will attempt to
maintain operation. An open high-voltage, low-current fuse (located in the high-voltage Bussed Electrical
Center (BEC)) may cause the DC/DC and Air Conditioning Compressor Module (ACCM) to be
non-functional, resulting in the 12-volt battery eventually becoming drained. Reduced or no functionality of
12-volt systems (headlamps, HVAC blower motor, etc.) may also be noticed.
• DTC P0AFA:13 (Hybrid Battery System Voltage Low: Circuit Open) - Sets when the difference in
high voltage between the TCM and DC/DC is greater than 150 volts.

• High-voltage low-cuent fuse
• DC/DC
PINPOINT TEST D: DTC P0AFA:13

D1 CHECK THE HIGH-VOLTAGE BEC
HIGH-VOLTAGE LOW-CURRENT FUSE
Yes
WARNING: Never install the service disconnect GO to D2 .
plug with the high-voltage bussed electrical center
(BEC) cover removed. Always install the cover prior No
to connecting the service disconnect plug. The INSTALL a new high-voltage,
high-voltage BEC cover prevents inadvertent contact low-current fuse. INSPECT the
with the high voltage which is present at several high-voltage BEC for signs of an
points under the cover. Failure to follow these obvious short condition. INSTALL a
instructions may result in serious personal injury or new high-voltage BEC as needed. If an
death. obvious short condition is not
identified, CARRY OUT self-test of
• Ignition OFF. the Battery Energy Control Module
• Depower the HVTB . Refer to Section 414-03 . (BECM). REFER to Section 414-03 to
• Remove the high-voltage BEC cover. Refer to the diagnose BECM DTCs.
High-Voltage Low-Current Fuse procedure in Section
414-03 .
PINPOINT TEST C: DTC P0AF7:00 5668

• Inspect and measure the resistance of the high-voltage

low-current fuse.
• Is the fuse undamaged and the resistance less than 5

ohms?
D2 CARRY OUT TESTING OF THE HIGH-VOLTAGE
CABLES
Yes
• Disconnect: DC/DC C1457A. GO to D3 .
• Disconnect: High-Voltage BEC C4236A.
• Measure the resistance between DC/DC C1457A, No
harness side and high-voltage BEC C4236A, harness INSTALL new high-voltage cables.
side as follows: REFER to Section 414-03 . CLEAR the
DC/DC Circuit High-Voltage BEC

C1457A-2 HYT03 (OG/WH) C4236A-2
C1457A-1 HYT04 (OG/BK) C4236A-1

D3 CHECK HIGH VOLTAGE TO THE TCM USING PID
BATTERY VOLTAGE ( TCM ) RECEIVED (HVBAT_V)
Yes
• Connect: DC/DC C1457A. GO to D4 .
• Connect: High-Voltage BEC C4236A.
• Install the HVTB service disconnect. Refer to Section No
414-03 . GO to D5 .
• Ignition ON.
DataLogger - TCM .
• Monitor the TCM PID HVBAT_V.
• Does the PID read greater than 150 volts?
PINPOINT TEST D: DTC P0AFA:13 5669

D4 CHECK HIGH VOLTAGE TO THE DC/DC USING

PID HEV HIGH VOLTAGE BUS-MEASURED
(HEVHiVolt)
Yes
• Enter the following diagnostic mode on the scan tool: GO to D5 .
DataLogger - DC/DC .
• Monitor the DC/DC PID HEVHiVolt. No
• Does t read greater than 150 volts? INSTALL a new DC/DC . REFER to
Direct Current/Direct Current (DC/DC)
Converter in this section. REPEAT the
operation.
D5 CLEAR DTCs AND CARRY OUT SELF-TEST OF
THE DC/DC
Yes
• Using the scan tool, clear the DC/DC DTCs. INSTALL a new DC/DC . REFER to
• Enter the following diagnostic mode on the scan tool: Direct Current/Direct Current (DC/DC)
Self Test - DC/DC . Converter in this section. REPEAT the
• Is DTC P0AFA:13 reported? self-test. TEST the system for normal
operation.
No
Concern is not present at this time.
CLEAR the DTC. REPEAT the
operation.
Pinpoint Test E: DTC P0AFA:16
Normal Operation
Voltage Traction Battery (HVTB). If the DC/DC senses high voltage of less than 150 volts, it will set DTC
P0AFA:16 and request the CHECK CHARGING SYSTEM message be displayed in the message center. The
DC/DC will be in standby mode ( DC/DC disabled) until the low-voltage condition clears, resulting in the
12-volt battery eventually becoming drained. Reduced or no functionality of 12-volt systems (headlamps,
HVAC blower motor, etc.) may also be noticed.
• DTC P0AFA:16 (Hybrid Battery System Voltage Low: Circuit Voltage Below Threshold) - Sets
when the DC/DC senses HVTB voltage of less than 150 volts.

• Identify subsystem which is source of HVTB system fault
PINPOINT TEST E: DTC P0AFA:16

E1 CHECK FOR DC/DC DTC

P0AFA:13
Yes
• Ignition ON. GO to Pinpoint Test D .
mode on the scan tool: Self Test - GO to E2 .
DC/DC .
• Is DTC P0AFA:13 reported?
E2 CHECK HIGH VOLTAGE TO
THE TCM USING PID BATTERY
VOLTAGE ( TCM ) RECEIVED
(HVBAT_V)
Yes
• Enter the following diagnostic GO to Pinpoint Test D .
mode on the scan tool:
DataLogger - TCM . No
• Monitor the TCM PID CARRY OUT self-test of the Battery Energy Control Module
HVBAT_V. (BECM). REFER to Section 414-03 for diagnosis of the
• Does the PID read greater than BECM DTCs. CLEAR the DTCs. REPEAT the self-test.
150 volts? TEST the system for normal operation.
Pinpoint Test F: DTC P0AFB:17
Normal Operation
Voltage Traction Battery (HVTB). If the DC/DC senses high voltage of greater than 360 volts, it will set DTC
P0AFB:17 and request the CHECK CHARGING SYSTEM message be displayed in the message center. The
DC/DC will be in standby mode ( DC/DC disabled) until the high voltage condition clears, resulting in the
12-volt battery eventually becoming drained. Reduced or no functionality of 12-volt systems (headlamps,
HVAC blower motor, etc.) may also be noticed.
• DTC P0AFB:17 (Hybrid Battery System Voltage High: Circuit Voltage Above Threshold) - Sets
when the DC/DC senses HVTB voltage of greater than 360 volts.
This pinpoint test is intended to diagnose the following: li>HVTB system fault
PINPOINT TEST F: DTC P0AFB:17

F1 CHECK THE TCM AND AIR
CONDITIONING COMPRESSOR MODULE
FOR HIGH VOLTAGE OVER-VOLTAGE
DTCs
PINPOINT TEST E: DTC P0AFA:16 5671


• Connect the scan tool. GO to F2 .
the scan tool: Self Test - TCM , and record No
the results. DEPOWER the HVTB . REFER to Section 414-03 .
• Enter the following diagnostic mode on INSPECT the high-voltage cable ends for arcing or
the scan tool: Self Test - ACCM . terminal pull out. REPAIR as necessary. CLEAR the
• Is Transmission Control Module (TCM) DTC. REPEAT the self-test. TEST the system for
DTC P0A78:17, P0A7A:17, P1A07:16, normal operation.
P0A07:62 and/or Air Conditioning
Compressor Module (ACCM) DTC
P0AFB:17 present?
F2 CHECK HIGH VOLTAGE TO THE
DC/DC USING PID HEV HIGH VOLTAGE
BUS-MEASURED (HEVHiVolt)
Yes
• Enter the following diagnostic mode on CARRY OUT self-test of the Battery Energy Control
the scan tool: DataLogger - DC/DC . Module (BECM). REFER to Section 414-03 for
• Monitor the DC/DC PID HEVHiVolt. further diagnosis of the BECM DTCs. CLEAR the
• Does the PID read less than 360 volts? DTC. REPEAT the self-test. TEST the system for
normal operation.
No
DEPOWER the HVTB . REFER to Section 414-03 .
INSPECT the high-voltage cable ends for arcing or
terminal pull out. REPAIR as necessary. CLEAR the
DTC. REPEAT the self-test. TEST the system for
normal operation.
Pinpoint Test G: DTC U0300:00
Normal Operation
The DC to DC Converter Control Module (DC/DC) communicates with various modules over the High Speed
Controller Area Network (HS-CAN). If the DC/DC determines a software incompatibility fault is present, it
sets DTC U0300:00 and operates in offline mode (low-voltage set point and current limits at default settings).
Periodic or constant heavy electrical loads of the 12-volt system may cause the 12-volt battery to become
drained. Reduced functionality of 12-volt systems (headlamps, HVAC blower motor, etc.) may also be
noticed.
• DTC U0300:00 (Internal Control Module Software Incompatibility: No Sub Type Information) - Sets
due to a HS-CAN configuration error.

• HS-CAN fault
• DC/DC
PINPOINT TEST F: DTC P0AFB:17 5672

PINPOINT TEST G: DTC U0300:00

G1 CARRY OUT NETWORK TEST
Yes
• Ignition ON. REFER to Section 418-00 to diagnose the network concern.
mode on the scan tool: Network GO to G2 .
Test.
• Were any concerns identified
by the Network Test?
G2 CLEAR DTCs AND CARRY
OUT SELF-TEST OF THE DC/DC
Yes
• Using the scan tool, clear the INSTALL a new DC/DC . REFER to Direct Current/Direct
DC/DC DTCs. Current (DC/DC) Converter in this section. CLEAR the DTC.
• Enter the following diagnostic REPEAT the self-test. TEST the system for normal operation.
mode on the scan tool: Self Test
- DC/DC . No
• Is DTC U0300:00 reported? Concern is not present at this time. CLEAR the DTC.
Pinpoint Test H: DTC P0562 and U3003:16
Normal Operation
The DC to DC Converter Control Module (DC/DC) monitors the 12-volt battery system voltage internally at
the B+ terminal of the DC/DC . If the voltage drops below 10.5 volts while the ignition is ON, the DC/DC
sets DTC U3003:16 and requests CHECK CHARGING SYSTEM be displayed in the message center. The
DC/DC will be in standby mode ( DC/DC disabled) and the 12-volt battery will eventually be drained.
Reduced or no functionality of 12-volt systems (headlamps, HVAC blower motor, etc.) may also be noticed.
The PCM monitors the system voltage through the Battery Junction Box (BJB). If this voltage drops 1.5 volts
or more below the generator voltage desired, this DTC will be set after 30 seconds.
• DTC P0562 (System Voltage Low) - If the PCM detects a voltage from the charging system that is
1.5 volts lower than the DC/DC voltage desired, this DTC will be set.
• DTC U3003:16 (Battery Voltage: Circuit Voltage Below Threshold) - Sets if the 12-volt battery
system voltage is less than 10.5 volts.

• 12-volt battery
• DC/DC
PINPOINT TEST G: DTC U0300:00 5673

PINPOINT TEST H: DTC P0562 AND U3003:16

H1 CHECK THE DC/DC DTCs
Yes
• Review the DC/DC DTCs recorded during Inspection REPAIR all other DC/DC DTCs before
and Verification. repairing U3003:16. GO to the DC to
• Are any DC/DC DTCs other than U3003:16 DC Converter Control Module (DC/DC)
present? DTC Chart in this section.
No
GO to H2 .
H2 TEST BATTERY CONDITION
Yes
• Carry out the battery condition test. Refer to Section
414-01 . No
• Did the battery pass the condition test? INSTALL a new battery. CLEAR the
DTC. REPEAT the self-test. TEST the
H3 CHECK VOLTAGE AT THE DC/DC
Yes
• START the vehicle (Ready Indicator light ON). For DTC P0562, GO to H4 . For DTC
• Turn the headlamps on and the blower on high. U3003:16, GO to H7 .
• Measure the voltage of the battery.
No
GO to H6 .
• Measure the voltage between DC/DC C1457B, circuit

SDC02 (RD), harness side and DC/DC C1457C, circuit
• Does the DC/DC voltage match battery voltage?

H4 COMPARE PCM MODULE SUPPLY VOLTAGE
(VPWR) PID
PINPOINT TEST H: DTC P0562 AND U3003:16 5674

• With the engine still running at idle, headlamps on and Yes

blower on high, measure the battery voltage at the GO to H5 .
battery and monitor the PCM VPWR PID.
No
REPAIR high resistance or loose
connections in the affected PCM power
circuit(s). CLEAR the DTCs. REPEAT
normal operation.
• Does PCM VPWR PID display battery voltage

within ±0.5 volt?
H5 CHECK PCM GROUND FOR HIGH RESISTANCE
Yes
• Monitor PCM VPWR PID. GO to H7 .
• With the engine still running at idle, turn off all
accessory loads, measure the battery voltage at the No
battery and note the PCM VPWR PID. REPAIR the affected PCM ground
circuits. CLEAR the DTCs. REPEAT
normal operation.
• With the engine still running at idle, turn headlamps on

and blower on high, measure the battery voltage at the
battery and monitor the PCM VPWR PID.
• Does the VPWR PID read within ±0.5 volt with

accessory loads on as compared to accessory loads
off?
H6 MEASURE VOLTAGE DROP OF DC/DC B+
CIRCUIT
PINPOINT TEST H: DTC P0562 AND U3003:16 5675

• Measure the voltage between DC/DC C1457B, circuit Yes

SDC02 (RD), harness side and the positive battery REPAIR DC/DC B- circuit GD108
terminal. (BK/VT) or INSTALL a new cable, if
necessary. CLEAR the DTC. REPEAT
normal operation.
No
REPAIR DC/DC B+ circuit SDC02
(RD) or INSTALL a new cable, if
necessary. CLEAR the DTC. REPEAT
normal operation.
H7 CLEAR DTCs AND CARRY OUT SELF-TEST OF
THE DC/DC
Yes
• Connect the scan tool. INSTALL a new DC/DC . REFER to
• Using the scan tool, clear the DC/DC DTCs. Section 414-03 . CLEAR the DTC.
• Enter the following diagnostic mode on the scan tool: REPEAT the self-test. TEST the system
Self Test - DC/DC . for normal operation.
• Is DTC U3003:16 reported?
No
time. The concern may have been
caused by a discharged battery.
Pinpoint Test I: DTC P0563 and U3003:17
Normal Operation
the B+ terminal of the DC/DC . If the voltage is greater than 16 volts, the DC/DC sets DTC U3003:17 and
requests CHECK CHARGING SYSTEM be displayed in the message center. The DC/DC will be in standby
mode ( DC/DC disabled) and the 12-volt battery will eventually be drained. Reduced or no functionality of
12-volt systems (headlamps, HVAC blower motor, etc.) may also be noticed.
The PCM also monitors system voltage and will set a DTC if the system voltage rises above a set threshold.
• DTC P0563 (System Voltage High) - If the PCM detects a voltage from the charging system higher
than 15.2 volts with vehicle speed above 8 km/h (5 mph), this DTC will be set.
• DTC U3003:17 (Battery Voltage: Circuit Voltage Above Threshold) - Sets if the 12-volt battery
system voltage is greater than 16 volts.

• 12-volt battery jump started or incorrectly charged
• Customer-installed accessory
• DC/DC

PINPOINT TEST I: DTC P0563 AND U3003:17

I1 CHECK VOLTAGE AT THE
DC/DC
Yes
• START the vehicle (Ready GO to I3 .
Indicator light ON).
• Turn off the headlamps,
blower and any other
accessories.
• Measure the voltage of the
battery.
• Is the voltage less than 16

volts?
I2 TEST BATTERY CONDITION
Yes
• Ignition OFF. GO to I4 .
• Carry out the battery condition
test. Refer to Section 414-01 . No
• Did the battery pass the DTC U3003:17 or P0563 was most likely set due to the 12-volt
condition test? battery being recently jump started or incorrectly charged using a
battery charger. INSTALL a new battery. CLEAR the DTC.
REPEAT the self-tests. TEST the system for normal operation. If
DTC U3003:17 or P0563 is still present, GO to I3 .
I3 INSPECT VEHICLE
ACCESSORIES
Yes
• Ignition OFF. COMMUNICATE the accessory concern to the customer.
• Inspect the vehicle and disable CLEAR the DTC. REPEAT the self-tests. TEST the system for
any customer installed normal operation.
accessories.
• START the vehicle (Ready No
Indicator light ON). GO to I4 .
• Measure the voltage of the
battery.
PINPOINT TEST I: DTC P0563 AND U3003:17 5677

• Is the voltage less than 16

volts?
I4 CLEAR DTCs AND CARRY
OUT SELF-TEST OF THE DC/DC
AND PCM
Yes
• Ignition ON. INSTALL a new DC/DC . REFER to Direct Current/Direct
• Connect the scan tool. Current (DC/DC) Converter in this section. REPEAT the
• Using the scan tool, clear the self-tests. TEST the system for normal operation.
DC/DC and PCM DTCs.
mode on the scan tool: Self Concern is not present at this time. DTC U3003:17 or P0563 was
Test - DC/DC . most likely set due to the 12-volt battery being recently jump
• Enter the following diagnostic started or incorrectly charged using a battery charger. CLEAR
mode on the scan tool: Self the DTC. REPEAT the self-test. TEST the system for normal
Test - PCM. operation.
• Is DTC U3003:17 reported
in the DC/DC or is DTC
P0563 reported in the PCM?
Pinpoint Test J: DTC U3003:62
Normal Operation
the B+ terminal of the DC/DC . The DC/DC also monitors the PCM relay control circuit voltage and
compares that voltage to the voltage sensed internally at the B+ terminal. If the 2 voltages vary by greater than
4.3 volts, the DC/DC sets DTC U3003:62 and requests CHECK CHARGING SYSTEM be displayed in the
message center. The DC/DC will be in standby mode ( DC/DC disabled) and the 12-volt battery will be
drained. Reduced or no functionality of 12-volt systems (headlamps, HVAC blower motor, etc.) may also be
noticed.
• DTC U3003:62 (Battery Voltage: Signal Compare Failure) - Sets when the DC/DC senses greater
than 4.3 volts difference between the DC/DC B+ terminal and the PCM relay control circuit.

• DC/DC B+ cable mounting
• B+ cable fuse (200A)
• DC/DC

PINPOINT TEST J: DTC U3003:62

J1 CHECK THE PCM MODULE SUPPLY
VOLTAGE (VPWR) PID
Yes
• Measure and record the voltage of the battery. GO to J2 .
No
CARRY OUT a self-test of the PCM.
RECORD any DTCs and REFER to the
(PC/ED) manual.

• Entethe following diagnostic mode on the scan
tool: DataLogger - PCM.
• Monitor the VPWR PID.
• Does the VPWR PID match battery voltage?
J2 CHECK THE B+ CABLE
Yes
• Measure the voltage between DC/DC C1457B, GO to J3 .
circuit SDC02 (RD), and DC/DC C1457C, circuit
GD108 (BK/VT), harness side. No
VERIFY the B+ cable fuse (200A) is OK. If
OK, REPAIR the affected circuit(s). If not
OK, REFER to the Wiring Diagrams manual
to identify the possible causes of the circuit
short. CLEAR the DTC. REPEAT the
operation.
• Does the DC/DC voltage match battery

voltage?
J3 MEASURE VOLTAGE DROP OF DC/DC B+
CIRCUIT
Yes
• With the headlamps ON and the blower on high,
measure the voltage between DC/DC C1457B, No
circuit SDC02 (RD), harness side and the positive REPAIR DC/DC B+ circuit SDC02 (RD) or
battery terminal. INSTALL a new cable, if necessary. CLEAR
the DTC. REPEAT the self-test. TEST the
PINPOINT TEST J: DTC U3003:62 5679

• Is the voltage drop less 0.5 volt?

J4 CHECK THE PCM RELAY CONTROL INPUT
TO THE DC/DC
Yes
• Disconnect: DC/DC C1457D.
• Ignition ON. No
• Measure the voltage between DC/DC C1457D-7, VERIFY the Battery Junction Box (BJB) fuse
circuit CBK03 (GY), harness side and ground. 47 (10A) is OK. If OK, REPAIR circuit
CBK03 (GY). If not OK, REFER to the
the DTC. REPEAT the self-test. TEST the

J5 CLEAR DTCs AND CARRY OUT SELF-TEST
OF THE DC/DC
Yes
• Connect the scan tool. INSTALL a new DC/DC . REFER to Direct
• Using the scan tool, clear the DC/DC DTCs. Current/Direct Current (DC/DC) Converter in
• Enter the following diagnostic mode on the scan this section. CLEAR the DTC. REPEAT the
tool: Self Test - DC/DC . self-test. TEST the system for normal
• Is DTC U3003:62 reported? operation.
No
The system is operating correctly at this time.
The concern may have been caused by a loose
or corroded connection. REPEAT the
operation.
Pinpoint Test K: The DC/AC Inverter Does Not Operate Correctly - No Power at the AC Power Point
or the AC Power Point LED Indicator Flashes With the Key in ON Position
Normal Operation
The DC/AC inverter receives 12 volts DC at C2293A-1 and C2293A-3 and is grounded at C2293A-6. The
incoming DC power is internally converted to 60 Hz, 110 volt AC power that is output to the AC power point

from C2293B-1 (power) and C2293B-5 (neutral).
NOTE: The electrical device that is powered by the AC power point must not exceed 150 watts.
NOTE: If the green LED is flashing, the AC power point may be overloaded, overheated or shorted. Unplug
the electrical device from the AC power point and cycle the key. Refer to the Owner's Literature to determine
if the electrical device is appropriate for the AC power point.

• Fuses
• DC/AC inverter
• AC power point
PINPOINT TEST K: THE DC/AC INVERTER DOES NOT OPERATE CORRECTLY - NO POWER AT THE AC POWER
POINT OR THE AC POWER POINT LED INDICATOR FLASHES WITH THE KEY IN THE ON POSITION

K1 CHECK THE DC/AC INVERTER
VOLTAGE CIRCUITS
Yes
• Disconnect: DC/AC Inverter C2293A.
• Ignition ON. No
• Measure the voltage between DC/AC VERIFY the Smart Junction Box (SJB) fuses 4
inverter C2293A-1, circuit SBP04 (GN/RD), (30A) and 35 (10A) are OK. If OK, REPAIR the
harness side and ground; and between affected circuit(s). If not OK, REFER to the
DC/AC inverter C2293A-3, circuit CBP35 Wiring Diagrams manual to identify the possible
(YE/GY), harness side and ground. causes of the circuit short. TEST the system for
normal operation.

K2 CHECK THE DC/AC INVERTER
GROUND CIRCUIT
Yes
• Measure the resistance between DC/AC
inverter C22936, circuit GD139 (BK/YE), No
harness side and ground. REPAIR circuit GD139 (BK/YE). TEST the
PINPOINT TEST K: THE DC/AC INVERTER DOES NOT OPERATE CORRECTLY - NO POWER
5681
AT THE A

K3 CHECK THE AC POWER POINT
Yes
• Disconnect: SJB Fuse 4 (30A). GO to K4 .
• Disconnect: AC Power Point C2292. No
• Disconnect: DC/AC Inverter C2293B. REPAIR the affected circuit(s). TEST the system
• Measure the resistance between DC/AC for normal operation.
inverter C2293B, harness side and AC power
point C2292, harness side as follows:
AC
DC/AC Power
Inverter Circuit Point
C2293B-1 HYA01 C2292-1
(OG/GN)
C2293B-5 HYA02 C2292-3
(OG/WH)

Yes
• Measure the resistance between AC power GO to K5 .
point C2292-1, circuit HYA01 (OG/GN),
REPAIR the affected circuit(s). TEST the system
5682
AT THE A
• Measure the resistance between AC power

point C2292-3, circuit HYA02 (OG/WH),
• Are the resistances greater than 10,000

ohms?
Yes
harness side and C2292-3, circuit HYA02 No
(OG/WH), harness side. REPAIR the affected circuit(s). TEST the system

ohms?
K6 CHECK THE AC POWER POINT FOR A
SHORT TOGETHER
Yes
component side and C2292-3, circuit HYA02 No
(OG/WH), harness side. INSTALL a new AC power point. TEST the
5683
AT THE A

ohms?
K7 CHECK THE AC POWER POINT FOR AN
OPEN
Yes
• Measure the resistance between AC power INSTALL a new DC/AC inverter. REFER to
point outlet side, pin 1 and AC power point Direct Current/Alternating Current (DC/AC)
C2292, pin-3, component side. Inverter in this section. TEST the system for
normal operation.
No
INSTALL a new AC power point. REFER to
Alternating Current (AC) Powerpoint in this
• Measure the resistance between AC power

point outlet side, pin 2 and AC power point
C2292, pin-1, component side.
Pinpoint Test L: The DC/AC Inverter Does Not Operate Correctly - The AC Power Point LED
Indicator is Never On
schematic and connectoinformation.
Normal Operation
The DC/AC inverter receives 12 volts DC at C2293A-1 and C2293A-3 and is grounded at C2293A-6. The
incoming DC power is internally converted to 60 Hz, 110 volt AC power that is output to the AC power point
from C2293B-1 (power) and C2293B-5 (neutral). If a fault in the system is detected, the LED flashes or is off
when the key is in the ON position. The LED continuously illuminates if the system is operating correctly
when the key is in the ON position.


• Fuses
• DC/AC inverter
• AC power point
PINPOINT TEST L: THE DC/AC INVERTER DOES NOT OPERATE CORRECTLY - THE AC POWER POINT LED
INDICATOR IS NEVER ON

L1 CHECK DC/AC INVERTER VOLTAGE
CIRCUIT
Yes
• Disconnect: DC/AC Inverter C2293A.
• Ignition ON. No
• Measure the voltage between DC/AC inverter VERIFY Smart Junction Box (SJB) fuse 35
C2293A-3, circuit CBP35 (YE/GY), harness side (10A). If OK, REPAIR circuit CBP35
and ground. (YE/GY). If not OK, REFER to the Wiring
Diagrams manual to identify the possible
causes of the circuit short. TEST the

L2 CHECK DC/AC INVERTER GROUND CIRCUIT
Yes
• Measure the resistance between DC/AC inverter
C2293A-6, circuit GD139 (BK/YE), harness side No
and ground. REPAIR circuit GD139 (BK/YE). TEST

L3 CHECK AC POWER POINT LED INDICATOR
PINPOINT TEST L: THE DC/AC INVERTER DOES NOT OPERATE CORRECTLY - THE AC POWER
5685 POIN
• Disconnect: SJB Fuse 4 (30A). Yes

• Disconnect: SJB Fuse 35 (10A). GO to L4 .
• Disconnect: DC/AC Inverter C2293B.
• Disconnect: AC Power Point C2292. No
• Measure the resistance between DC/AC inverter REPAIR the affected circuit(s). TEST the
C2293B, harness side and AC power point C2292 system for normal operation.
as follows:
DC/AC AC Power
Inverter Circuit Point
C2293B-9 LYA03 C2292-6
(YE/VT)
C2293B-8 RYA03 C2292-5
(BU/BN)

L4 CHECK THE AC POWER POINT LED
Yes
• Using the digital multimeter diode check function, INSTALL a new DC/AC inverter. REFER
test the diode between AC power point C2292, to Direct Current/Alternating Current
pin-5 and pin-6, component side in both directions. (DC/AC) Inverter in this section. TEST the
No
INSTALL a new AC power point. REFER
to Alternating Current (AC) Powerpoint in
this section. TEST the system for normal
operation.
• Is the diode OK?
5686 POIN
5687 POIN
Alternating Current (AC) Powerpoint

1 19N236 AC power point
2 - Floor console end cover
3 - AC power point electrical connector (part of 14300)
4 - Floor console
5 W711401 Floor console rear screws (2 required)
WARNING: Disconnect the battery before servicing the direct current/alternating (DC-AC)
inverter or alternating current (AC) powerpoint to prevent the risk of high voltage shock. Failure to
follow this instruction may result in serious personal injury.
1. Disconnect the 12-volt battery. For additional information, refer to Section 414-01 .
2. NOTICE: Make sure that the rear of the floor console is lifted away from the floor as specified.
Failure to follow this procedure will result in damage to the floor console and the tabs at the top
of the floor console end cover.
Remove the floor console rear screws and lift the floor console about 25 mm (0.984 in) away from the
floor.
3. Remove the floor console end cover by pulling the cover away at the bottom and rotating out. Lower
the cover 7-13 mm (0.275-0.511 in) to clear the tabs on the top of the floor console end cover.
4. Disconnect the electrical connector and remove the AC power point by depressing the 4 tabs
as shown.
Alternating Current (AC) Powerpoint 5688

Alternating Current (AC) Powerpoint 5689

Direct Current/Alternating Current (DC/AC) Inverter

1 - DC/AC inverter wiring connector (part of 14300)
2 - DC/AC inverter wiring connector (part of 14A005)
3 19G317 DC/AC inverter
4 W707142 DC/AC inverter nuts (3 required)
WARNING: Disconnect the battery before servicing the direct current/alternating (DC-AC)
inverter or alternating current (AC) powerpoint to prevent the risk of high voltage shock. Failure to
follow this instruction may result in serious personal injury.
2. Remove 4 pin-type retainers and the front trunk cover.
backrest from lowering, raise thekrest upward to release the safety belt retractor and belt webbing.
Fold the RH backrest down.
Direct Current/Alternating Current (DC/AC) Inverter 5690

5. Disconnect the 2 electrical connectors at the DC/AC inverter.
6. Remove the 3 nuts and the DC/AC inverter.

Direct Current/Alternating Current (DC/AC) Inverter 5691

Direct Current/Direct Current (DC/DC) Converter
Part
1 W503924 A/C tube bracket bolt
2 W713417 DC to DC Converter Control Module (DC/DC) top
bracket bolts (3 required)
3 14B303 DC/DC top bracket
4 - DC/DC low-voltage electrical connector
5 14B227 DC/DC assembly
6 W712524 DC/DC lower LH bracket bolts (2 required)
7 - DC/DC coolant inlet/ outlet tubes
8 W520513 DC/DC low-voltage battery cable nuts (2 required)
9 W520102 DC/DC lower RH bracket nut
service instructions, including instructions to depower the system. The high-voltage hybrid system utes
1. Depower the High Voltage Traction Battery (HVTB). For additional information, refer to Section
414-03 .
3. Remove the A/C tube bracket bolt and the 3 DC to DC Converter Control Module (DC/DC) top
bracket bolts. Remove the bracket.
• To install, tighten the 3 DC/DC top bracket bolts to 9 Nm (80 lb-in).
• To install, tighten the A/C tube bracket bolt to 6 Nm (53 lb-in).
Direct Current/Direct Current (DC/DC) Converter 5692


Disconnect the DC/DC high-voltage and interlock connector as follows:
1. Press the locking tab on the white interlock connector and partially disconnect the connector
from the DC/DC .
2. Press the locking tab on the orange high-voltage connector and fully disconnect both
connectors from the DC/DC .
5. Disconnect the DC/DC low-voltage connector.
6. WARNING: Always tighten the DC/DC converter low-voltage battery cable fasteners to
specification. Loose connections may result in electrical arcing, which increases both the risk of
fires and serious personal injury.
Remove the 2 DC/DC low-voltage battery cable nuts and position the low-voltage battery cables
aside.
7. Clamp the Motor Electronics Cooling System (MECS) hoses to prevent coolant from leaking from the
hoses during the repair.
8. Loosen the hose clamps and remove the MECS hoses from the DC/DC .
9. Remove the DC/DC lower RH bracket nut.

10. Detach the wire harness from the lower LH side of the DC/DC .
11. NOTICE: Do not remove the DC to DC Converter Control Module (DC/DC) LH lower bracket
from the vehicle rail, as this may degrade the vehicle ground attachment and DC/DC alignment.
NOTE: If a new DC/DC is being installed, the new DC/DC will come with a new LH lower bracket
attached. Remove the LH lower bracket from the new DC/DC and discard. Whenever possible, re-use
the LH lower bracket which has been left attached to the vehicle. If the a new bracket is being
installed, make sure the surfaces between the bracket and side rails are clean and free of grease, dirt
and debris.
Remove the 2 lower LH DC/DC bracket bolts and remove the DC/DC .

13. Refill the MECS after installation. Bleed any air from the system. For additional information, refer to
Section 307-02B .

SECTION 415-00: Information and Entertainment 2012 Fusion, MKZ, Fusion Hybrid, MKZ
Systems Hybrid Workshop Manual
Antenna cable bolt 8 71
Antenna module bolt 12 106
Audio Digital Signal Processing (DSP) module bolts 9 80
Engine ground strap 9 80
Radio interference capacitor (body) 7 62
Speaker enclosure mounting bolts 8 71
Subwoofer amplifier screws 5 44

Information and Entertainment System
Functional Components
The functional components of the audio system are:
• Audio Front Control Module (ACM)

• Accessory Protocol Interface Module (APIM), located toward the rear end of the floor console
• Audio Digital Signal Processing (DSP) module, located in the RH side of the luggage compartment
• Subwoofer amplifier, located in the RH side of the luggage compartment
• Audio amplifier, located in the RH side of the luggage compartment
• Global Positioning System Module (GPSM), located in the instrument panel
• Speakers (see Audio Line-Up for locations)
• AM/FM antenna (Fusion) located at the rear of the roof
• Antenna module (MKZ), located at the RH C-pillar
• AM/FM/satellite radio combination antenna (Fusion), located at the rear of the roof
• Satellite radio antenna (MKZ), located at the rear of the roof
• Global Positioning System (GPS) antenna (integral to the AM/FM/satellite radio antenna (Fusion) or
the satellite radio antenna (MKZ))
• AM/FM antenna cable (must be overlaid on harness)
• Satellite radio antenna cable (must be overlaid on harness)
• Steering wheel controls
• Universal Serial Bus (USB) port and cable, located in the floor console stowage bin
• Audio input jack, located in the floor console stowage bin (vehicles with the SYNC® system) or at
the front of the floor console (vehicles without the SYNC® system)
• Clockspring
• Microphone
Audio Line-Up
The vehicle is equipped with one of the following audio systems:
• Base - Fusion
♦ AM/FM/CD ACM with MP3
♦ Four speakers (1 in each door)
• Mid-Level - Fusion
♦ AM/FM/CD with MP3
♦ Six speakers (1 in each door, 1 sail-mounted tweeter in each front door)
• Premium Sound - MKZ
♦ AM/FM/CD ACM with MP3 (standard)
♦ Navigation ACM with HD Radio® and built-in single CD/DVD drive (optional)
♦ Nine speakers (one1 speaker in each front door, 1 speaker in each rear door, 1 tweeter in each
front door, 1 instrument panel speaker, 2 parcel shelf-mounted subwoofers)
♦ Audio amplifier and subwoofer amplifier
• Sony® Sound - Fusion
Information and Entertainment System 5696

♦ Twelve speakers (1 speaker in each front door, one 2-way speaker in each rear door, 1 tweeter
in each front door, 1 instrument panel speaker, 1 parcel shelf speaker, 2 parcel shelf-mounted
subwoofers)
♦ Audio DSP module
• THX® A
♦ Fourteen speakers (1 speaker in each front door, one 2-way speaker in each rear door, 1
tweeter in each front door, one 3-way instrument panel speaker, 1 parcel shelf speaker, 2
parcel shelf-mounted subwoofers)
♦ Audio DSP module
All audio systems include the following features:
• Speed sensitive volume

• Accessory delay
• MP3 capability
• Audio input jack
The following options are also available:

• Satellite radio
♦ Provides satellite broadcast audio channels
• SYNC® System
♦ Provides mobile phone and media device functionality with the vehicle audio system
AM/FM Antenna - Fusion
The antenna can be either an AM/FM antenna or a combination AM/FM/satellite radio antenna if the vehicle
is equipped with satellite radio.
AM/FM Antenna - MKZ
The AM/FM antenna is located in the rear glass. It cannot be replaced separate from the rear glass.
Satellite Radio
The satellite radio system is comprised of the following:
• Satellite radio receiver built-in to the ACpan>

• Combination AM/FM/satellite radio antenna (Fusion)
• Standalone satellite radio antenna (MKZ)
• Satellite radio antenna cable
The satellite radio antenna is a stand-alone antenna on the MKZ, or is a combination AM/FM/satellite antenna
on the Fusion. The satellite radio antenna cable connects the satellite radio antenna to the ACM .
The satellite radio antenna cable is not removable from the wiring harnesses.
Navigation System with HD Radio®
The navigation system consists of the following:

• Navigation ACM
• GPS antenna
• Satellite radio/ GPS splitter cable (part of the front satellite radio antenna cable)
• Microphone
The ACM controls the operation of the navigation system and the audio system. The system uses a GPS
antenna, a vehicle speed input, and other sensor information to accurately establish the vehicle position.
SYNC® System
The SYNC® system consists of the following:
• APIM
• SYNC®-specific steering wheel controls
• Microphone
• USB port and cable
SYNC® is a hands-free communications and entertainment system that allows the following interactions:
• Send and receive phone calls via a Bluetooth-enabled phone

• Send and receive text messages via a Bluetooth-enabled phone
• Connect media devices (such as an iPod® or USB flash device) in order to play audio files
• Play media files via a Bluetooth-enabled audio device
• Produce vehicle health reports
• Initiate an emergency call (eCall) when the air bags deploy
• Provide hands-free access to traffic reports, turn-by-turn driving directions, business listings, news,
sports, and weather
The GPSM works with the SYNC® system to provide vehicle location on vehicles not equipped with
navigation, as the vehicle location must be known for the traffic, directions, and information features to
operate correctly.
Not all features are available with every phone.
For additional information on audio system operation, including the SYNC® system, refer to the Owner's
Literature.


Information and Entertainment System
Special Tool(s)


Flex Probe Kit
Multi-Media Interface Tester

105-00120
Universal Serial Bus (USB) Male-A To

Male-A Cable
CCMUSB2-AM-AM-10
Audio Front Control Module (ACM)
The Audio Front Control Module (ACM) can be operated with the key in RUN or ACC. The accessory delay
feature allows the audio system to be operated for a preset period of time after the key is turned off and a front
door has not been opened. The ACM sends AC voltage audio signals to the speakers or to the amplifiers,
depending on vehicle configuration. The ACM can produce its own DTCs, which can be communicated to the
scan tool through the Medium Speed Controller Area Network (MS-CAN).
Front Controls Interface Module (FCIM)
The Front Controls Interface Module (FCIM) acts as a customer interface with the audio system and the
climate control system. When a switch is pressed, a message is broadcast over the MS-CAN . When a climate
control switch is pressed, the HVAC module sends a message back to the FCIM to illuminate the correct
switches to indicate the status of the climate control system.
Front Display Interface Module (FDIM)
For vehicles without navigation, the Front Display Interface Module (FDIM) is a stand-alone module. It
receives messages for all of its displays, which include:
• Audio information
• Climate control fan speed and temperature setting
• Outside air temperature

• Compass heading
For vehicles with navigation, the FDIM is hardwired to the ACM . When the touchscreen is pressed, a signal
is sent to the ACM , which acts on the signal either by changing the audio setting or by broadcasting a
message via the MS-CAN to the module controlling the function that was selected. The audio system,
navigation, and climate control video feed to the FDIM is provided by the ACM . If equipped with a rear view
camera, the video feed for the camera is provided directly by the rear view camera.
Satellite Audio
The satellite radio antenna receives digital audio signals and sends them to the ACM through the satellite
radio antenna cable.
Antenna â Fusion
The antenna receives AM/FM radio waves, and satellite radio signals (if equipped with satellite radio). All
audio signals are sent to the ACM through the antenna cables.
Antenna â MKZ
The antenna receives both AM and FM radio waves. The antenna is built into the rear window glass. An
antenna module is utilized to isolate the signals. The audio signals are then sent to the ACM through the
AM/FM antenna cable. If equipped with satellite radio, the satellite radio antenna is mounted to the roof. It
receives digital audio signals and sends them to the ACM .
SonyÂ® Sound
For vehicles with the SonyÂ® sound system, audio signals are sent from the ACM to the audio Digital Signal
Processing (DSP) module, which processes the audio signals and sends them to all of the speakers. The audio
DSP module uses internal software to produce an optimal sound environment. The audio DSP module
communicates on the MS-CAN . Customer preference settings such as fade and balance are broadcast to the
audio DSP module by the ACM .
THXÂ® Sound
For vehicles with the THXÂ® sound system, the audio DSP module provides theatre quality sound in the
vehicle. Audio signals are sent from the ACM to the audio DSP module, which processes the audio signals
and sends them to all of the speakers. An enable detection circuit is utilized for the amplifier (internal to the
audio DSP module). The circuit turns the amplifier on. The audio DSP module communicates on the
MS-CAN . Customer preference settings such as fade and balance are broadcast to the audio DSP module by
the ACM .
Navigation System
The vehicle navigation system guides the user to a pre-entered destination. No navigation map DVD is
needed, as the map guidance information is stored in the ACM hard-drive. The ACM calculates route
information based on Global Positioning System (GPS) data. The ACM also uses vehicle speed and
transmission gear selected signals received through the MS-CAN to detect vehicle speed and direction,
resulting in more accurate navigation tracking.
The navigation display is shown on the FDIM . Either the FDIM touchscreen or the buttons on the FCIM can
be used to interact with the navigation system.
The compass heading is derived from the GPS antenna signal. There are no serviceable parts for the compass.

A voice recognition system allows the user to interface with the system without using the touchscreen. A
microphone provides the voice recognition input. The microphone is shared with the SYNCÂ® system.
Jukebox Feature
The navigation ACM contains a 10 gigabyte on-board hard drive that is capable of storing music ripped
(recorded) from a music disc. The music can be loaded into the jukebox by inserting a disc (in the correct
format) and following the on-screen instructions to load the music into the ACM . The jukebox cannot rip
MP3 discs.
SYNCÂ® System
The SYNCÂ® system allows interaction with several types of customer devices, including mobile phones and
media devices. The APIM contains an on-board Bluetooth chipset, which enables certain wireless devices to
interact with the system.
The APIM consists of 2 internal modules: the Consumer Interface Processor (CIP) and the Vehicle Interface
Processor (VIP). The modules are not replaceable individually, but can be flashed independently, if required.
The CIP interfaces with all of the inputs to the APIM . The CIP contains an analog-to-digital-to-analog
converter, as well as the Bluetooth chipset. Any consumer-available application upgrades that are available
are loaded directly to the CIP through the USB port.
The VIP provides an interface between the CIP and the vehicle. The main functions of the VIP are controlling
the APIM power management and translating both inbound and outbound signals over the CAN .
The APIM can receive inputs from the following audio sources:
• USB port
• Bluetooth
The USB port can be used for connecting a media device (such as an iPodÂ®) with the device's available
cable, or for directly plugging in a portable mass storage device (such as a "thumb drive"). When playing
media files stored on a mass storage device, the SYNCÂ® system only plays files that do not have Digital
Rights Management (DRM) protection. The USB port can also be used for uploading vehicle application
upgrades.
The USB port is powered by the APIM , so no external power source is needed to power a device plugged into
the USB port if the device supports this feature.
The audio input jack can be used for connecting a media device (such as an iPodÂ®) utilizing a 1/8-inch
audio jack. When a device is connected through the audio input jack, only the speaker volume can be
controlled by the ACM . All other functions (such as seek, fast forward, pause, etc.) must be carried out on the
device itself.
The Bluetooth interface can accommodate both Bluetooth-enabled mobile phones and Bluetooth-enabled
media devices. Any Bluetooth device used with the SYNCÂ® system must first be paired with the system
before it is operational.
Bluetooth is a secure, short-range radio frequency that allows devices to communicate wirelessly through
radio waves. The operating range of a Bluetooth signal is a maximum of 32 feet.
Only one Bluetooth phone and one Bluetooth media device can be connected to the system at any one time. If

an additional device of either type is paired with the system and made active, the APIM will disconnect any
active connection and establish a connection with the new device.
It is important to understand that not all mobile phones will have the same level of features when interacting
with the SYNCÂ® system. For a list of compatible phones, refer to the SyncMyRide website .
In addition to audio information, metadata may also be sent to the APIM from a device plugged into the USB
port. Metadata consists of such information as artist, album title, song title, and genre. The metadata is used
by the APIM to create indexes that can be used to sort for particular music, based on customer preference. Not
all USB devices can send metadata to the APIM ; also, no metadata is transferred when a device is connected
through the audio input jack. When a new media device is connected to the SYNCÂ® system, the APIM
automatically indexes the information. This may take several minutes (depending on the amount of data on
the device), and is considered normal operation. When a device that was previously connected to the
SYNCÂ® system is reconnected, the APIM updates the index (rather than creating a new one), which reduces
the amount of time needed to create the index.
The APIM receives both stereo and mono sound inputs, and can also transmit both stereo and mono sound.
The mono function is used to receive the microphone input, and to send sound to the ACM for voice prompts,
the Text-To-Speech (TTS) feature, ring tones, and any audio received through a connected mobile phone. The
TTS feature speaks information so that it does not have to be read from the display.
The APIM communicates on the MS-CAN and High Speed Controller Area Network (HS-CAN).
Communication with the scan tool is established through the HS-CAN .
Global Positioning System Module (GPSM)
The Global Positioning System Module (GPSM) provides vehicle location for real-time traffic reports and
re-routing, and for identifying vehicle location in the event of a collision. The vehicle location information is
broadcast to the APIM over the MS-CAN . The GPSM is part of the SYNCÂ® system and is only present for
vehicles without navigation.
Voice Recognition For Vehicles With Navigation And The SYNCÂ® System
When the audio system enters voice recognition mode, the ACM initially controls the voice recognition
feature. The microphone is wired directly to the APIM , which relays the microphone input to the ACM
through dedicated wiring. If the first command spoken is part of the ACM voice recognition set, the ACM
retains control of the voice recognition and takes the appropriate action(s). If the first command spoken is part
of the APIM voice recognition set, the ACM shuts off its own voice recognition and broadcasts a Controller
Area Network (CAN) message to the APIM , transferring the voice recognition to the SYNCÂ® system and
providing the voice command that was spoken. The ACM controls the voice engine for the base audio,
navigation, and climate control systems. The APIM controls the voice engine for the SYNCÂ® system ( USB
port, audio input jack, Bluetooth).
Steering Wheel Controls
The steering wheel controls consist of a series of resistors. Each steering wheel control switch function
corresponds with a specific resistance value within the switch. When a switch is pressed, the ACM (or the
APIM ) monitors the change in reference voltage to determine the requested function.
Noise Suppression Equipment
The radio frequency suppression equipment reduces interference transmitted through the speakers by the
engine ignition and electrical systems. When installing any new radio suppression equipment components,
make sure that a good contact is made at all connections.

Audio Signals
Audio signal flow varies greatly depending on vehicle content.
Stereo signals contain left and right channel information, and are used for most audio signals.
A mono signal is used for the microphone input to the APIM . The mono signal is also used for the voice
prompts, the TTS feature, ring tones, and any audio received through a connected mobile phone. These audio
signals are output from the APIM to the ACM . The mono and stereo outputs from the APIM utilize separate
circuits.
A digital signal is used to transmit data from a media device connected through the USB port to the APIM .
The APIM then converts the signal to analog and relays the signal to the ACM .
A wireless signal is used to broadcast audio signals from a Bluetooth device to the APIM . As with a digital
signal sent through the USB port, the APIM converts the wireless audio signal to analog and relays it to the
ACM .
Network Communication
The following audio system components communicate via the MS-CAN :
• ACM
• Navigation ACM
• Audio DSP module (SonyÂ® sound)
• Audio DSP module (THXÂ® sound)
• FCIM
• FDIM (vehicles without navigation)
• APIM
• GPSM
There are numerous messages internal to the audio system. The functions of these messages include (but are
not limited to):
• Changing the audio source

• Changing equalizer settings
• Updating the FDIM display
• Dialing phone numbers from the FCIM (if equipped with the SYNCÂ® system)
In addition, the following messages are utilized by the audio system in conjunction with systems outside of
the audio system:
Audio System
Transmitting Receiving
Message Module Module(s) Audio System Function
Accelerometer and Instrument Panel GPSM Provides vehicle yaw rate to the GPSM for use in
Yaw Sensor Data Cluster (IPC) vehicle tracking.
Accessory Delay SJB ACM When active, this signal allows the audio component
Status to be operated after the vehicle is shut off.
APIM

FCIM
FDIM
Average Fuel IPC ACM Provides average fuel economy data to the ACM .
Economy Data
Belt-MinderÂ® IPC ACM When this signal is active, the speaker output is
Status reduced to allow the Belt-MinderÂ® tone to be more
easily heard. This message only applies to vehicles
with MyKey that have this feature currently enabled.
Climate Control HVAC module ACM Provides the outside air temperature to the ACM .
Data (Hybrid only)
Compass Display IPC FDIM Indicates the compass heading or mode (calibration,
Status zone). This message only applies to vehicles without
navigation.
eCall Notification Restraints APIM Provides the eCall status to the APIM . This message
Control Module is also used to confirm that the APIM and RCM are
(RCM) both configured for the eCall feature.
eCall Status APIM RCM Provides the eCall status to the RCM . This message
is also used to confirm that the APIM and RCM are
both configured for the eCall feature.
English/Metric Mode IPC ACM Indicates whether English or metric units is currently
selected.
FCIM Button Press FCIM ACM Indicates when a button is pressed on the FCIM so
Data the audio system can make the desired setting
APIM change.
Audio DSP
module
IPC
Fuel Level (Instant) IPC APIM Provides the instant fuel level to the APIM .
Historical Fuel IPC ACM Provides the historical fuel economy data to the ACM
Economy (Hybrid for display on the FDIM . This message only applies
only) to vehicles with navigation.
HVAC Button Status ACM HVAC Indicates when a climate control setting is changed
(from ACM ) module using the FDIM touchscreen (which is hardwired to
the ACM ) so the HVAC module can make the
desired setting changes. This message only applies to
vehicles with navigation.
HVAC Button Status FCIM HVAC Indicates when a climate control button is pressed on
(from FCIM ) module the FCIM so the HVAC module can make the desired
setting change.
HVAC Indicator HVAC module ACM Indicates the mode of the HVAC module so the ACM
Status (to ACM ) can send the correct display information to the FDIM
. This message only applies to vehicles with
navigation.
HVAC Indicator HVAC module FCIM Indicates the mode of the HVAC module so the
Status (to FCIM ) FCIM can illuminate the appropriate indicator on the
bezel face.
HVAC module

HVAC Module ACM (with Indicates certain climate control settings such as
Display Data navigation) temperature, fan speed, air distribution, and outside
air temperature.
FDIM
(without
navigation)
HVAC Voice ACM HVAC Provides climate control setting changes that are
Request module initiated through the voice recognition system. This
message only applies to vehicles with navigation.
Ignition Switch SJB ACM Indicates the ignition position to the audio system
Position modules in order to control power management.
APIM
Audio DSP
module
FCIM
FDIM
GPSM
Instrument SJB ACM Controls the backlight intensity, based on the position
Illumination Level of the dimmer switch.
FCIM
FDIM
Navigation Rolling IPC ACM Used by the ACM to more accurately track vehicle
Wheel Count position when the GPS signal is temporarily
GPSM unavailable.
Used by the GPSM for vehicle tracking if the vehicle

speed signal is lost.
Odometer Rolling PCM APIM Provides the odometer reading to the APIM in order
Count to initiate maintenance interval notifications.
Park Brake Status SJB ACM Provides the park brake status to the ACM .
Parking Aid Sounder Parking Aid ACM When this signal is active, the speaker output is
Volume Cutback Module (PAM) reduced to allow the parking aid tone to be more
Request easily heard.
Power Flow Status IPC ACM Provides the approximate power flow data to the
(Hybrid only) ACM for display on the FDIM . This message only
applies to vehicles with navigation.
TPMS Status SJB APIM Provides the current tire pressure and TPMS warning
(Hybrid only) indicator status to the APIM .
Transmission IPC ACM For the navigation system, this signal is used for
Selector (PRNDL) more accurate navigation tracking.
Status GPSM
For the parking aid system, this signal is used by the
ACM to determine if it should enable the speaker
mute feature when a parking aid tone sounds.
For vehicles with a rear view camera, this signal is

used by the ACM to determine if it should allow the

video feed from the rear view camera to be shown on

the FDIM .
For vehicles with the SYNCÂ® system but not

navigation, this signal is used by the GPSM for more
accurate vehicle tracking.
Vehicle Speed IPC ACM Used by the ACM (or audio DSP module) for the
speed-compensated volume function.
Audio DSP
module Used by the GPSM for vehicle tracking.
GPSM
Vehicle IPC ACM Provides the VIN to verify the correct modules are
Identification installed.
Number (VIN) APIM
Information
• Front Controls Interface Module • Battery Junction Box (BJB)

(FCIM) fuse(s):
• Front Display Interface Module ♦ 20 (20A) (VBATT)
(FDIM) ♦ 21 (20A) (VBATT)
• Antenna • Smart Junction Box (SJB)
• Audio input jack fuse(s):
• Noise suppression equipment ♦ 13 (5A) (VBATT)
• Speaker(s) ♦ 14 (10A) (VBATT)
• Steering wheel controls ♦ 19 (25A) (VBATT)
• Universal Serial Bus (USB) port ♦ 28 (5A) (START
signal)
♦ 38 (20A) (VBATT)
♦ 39 (20A) (VBATT)
♦ 41 (15A)
(Accessory delay)
connectors




418-00 .
8. NOTE: Do not press any buttons on the FCIM or FDIM while the Audio Front Control Module
(ACM) is carrying out the self-test.
Clear the continuous DTCs and carry out the self-test diagnostics for the ACM .
10. If no DTCs related to the concern are retrieved, refer to the Symptom Charts.
DTC Charts
Audio Front Control Module (ACM) DTC Chart â Fusion Without Navigation

B1031 SDARS Satellite GO to Pinpoint Test B .
Antenna Open
B1032 SDARS Satellite GO to Pinpoint Test B .
Antenna Short
B1117 Audio Steering Wheel GO to Pinpoint Test Q .
Button Stuck
B1318 Battery Voltage Low GO to Pinpoint Test AO .
B1342 ECU is Faulted NOTE: DTC B1342 may set as a result of a speaker circuit fault. In this
case, DTC B2965 should also be set. Be sure to repair the speaker circuit
fault before diagnosing DTC B1342.
CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is the only DTC
retrieved again, INSTALL a new Audio Front Control Module (ACM).

REFER to Audio Control Module (ACM) â Fusion or Audio Control

Module (ACM) â MKZ in this section. TEST the system for normal
operation.
B2103 Antenna Not Connected GO to Pinpoint Test A .
B2404 Audio Steering Wheel GO to Pinpoint Test Q .
Switch Circuit Fault
B2406 Audio Disc CD Player NOTE: DTC B1342 may also be set.
Internal Fault
CLEAR the DTCs. REPEAT the self-test. If DTC B2406 is retrieved again,
INSTALL a new ACM . REFER to Audio Control Module (ACM) â
Fusion or Audio Control Module (ACM) â MKZ in this section. TEST
B2477 Module Configuration REFER to Section 418-01 .
Failure
B2965 Audio System Speaker For the base or mid-level audio system, GO to Pinpoint Test C .
Circuit Fault
For SonyÂ® sound, GO to Pinpoint Test E .
U0140 Lost Communication GO to Pinpoint Test AE .
With Body Control
Module ( GEM )
U0155 Lost Communication GO to Pinpoint Test AG .
With Instrument Panel
Cluster ( IC ) Control
Module
U0159 Lost Communication GO to Pinpoint Test U .
With Parking Assist
Control Module ( PAM )
U0197 Lost Communication GO to Pinpoint Test AK .
With Telephone Control
Module
U0238 Lost Communication GO to Pinpoint Test AL .
With Digital Audio
Control Module "D" (
DSP )
U0255 Lost Communication GO to Pinpoint Test AM .
With Front Controls
Interface Module
U0256 Lost Communication GO to Pinpoint Test AN .
With Front Display
Interface Module
U2050 No Application Present REFER to Section 418-01 .
U2051 One or More Calibration REFER to Section 418-01 .
Files Missing/Corrupt
Audio Front Control Module (ACM) DTC Chart â MKZ Without Navigation


B11BA:1C Steering Wheel Audio Switch Pack: GO to Pinpoint Test Q .
Circuit Voltage out of Range
B11BA:63 Steering Wheel Audio Switch Pack: GO to Pinpoint Test Q .
Circuit / Component Protection
Time-Out
B1A01:01 Speaker #1: General Electrical For premium sound, GO to Pinpoint Test D .
Failure
For THXÂ® sound, GO to Pinpoint Test F .
B1A01:11 Speaker #1: Circuit Short to Ground For premium sound, GO to Pinpoint Test D .

B1A01:12 Speaker #1: Circuit Short to Battery For premium sound, GO to Pinpoint Test D .

B1A01:13 Speaker #1: Circuit Open For premium sound, GO to Pinpoint Test D .

Failure
B1A02:11 Speaker #2: Circuit Short to Ground For premium sound, GO to Pinpoint Test D .

B1A02:12 Speaker #2: Circuit Short to Battery For premium sound, GO to Pinpoint Test D .

B1A02:13 Speaker #2: Circuit Open For premium sound, GO to Pinpoint Test D .

B1A03:01 Speaker #3: General Electrical GO to Pinpoint Test D .
Failure
B1A03:11 Speaker #3: Circuit Short to Ground GO to Pinpoint Test D .
B1A03:12 Speaker #3: Circuit Short to Battery GO to Pinpoint Test D .
B1A03:13 Speaker #3: Circuit Open GO to Pinpoint Test D .
B1A04:01 Speaker #4: General Electrical GO to Pinpoint Test D .
Failure
B1A04:11 Speaker #4: Circuit Short to Ground GO to Pinpoint Test D .
B1A04:12 Speaker #4: Circuit Short to Battery GO to Pinpoint Test D .
B1A04:13 Speaker #4: Circuit Open GO to Pinpoint Test D .
B1A05:02 Speaker #5: General Signal Failure GO to Pinpoint Test D .
B1A06:02 Speaker #6: General Signal Failure GO to Pinpoint Test D .
B1A56:21 Antenna: Signal Amplitude â © GO to Pinpoint Test A .
Minimum
B1A89:01 GO to Pinpoint Test B .

Satellite Antenna: General

Electrical Failure
B1A89:13 Satellite Antenna: Circuit Open GO to Pinpoint Test B .
B1D19:49 Compact Disc Unit: Internal CLEAR the DTCs. REPEAT the self-test. If DTC
Electronic Failure B1D19:49 is retrieved again, INSTALL a new Audio Front
Control Module (ACM). REFER to Audio Control Module
(ACM) â MKZ in this section. REPEAT the self-test.
B1D78:13 Auxiliary Input: Circuit Open GO to Pinpoint Test R .
U0140:00 Lost Communication With Body GO to Pinpoint Test AE .
Control Module: No Sub Type
Information
U0155:00 Lost Communication With GO to Pinpoint Test AG .
Instrument Panel Cluster ( IPC )
Information
U0159:00 Lost Communication With Parking GO to Pinpoint Test U .
Assist Control Module "A": No Sub
Type Information
U0197:00 Lost Communication With GO to Pinpoint Test AK .
Telephone Control Module: No Sub
Type Information
U0238:00 Lost Communication With Digital GO to Pinpoint Test AL .
Audio Control Module "D": No Sub
Type Information
U0255:00 Lost Communication With Front GO to Pinpoint Test AN .
Display Interface Module: No Sub
Type Information
U0256:00 Lost Communication With Front GO to Pinpoint Test AM .
Controls Interface Module: No Sub
Type Information
U2014:41 Control Module Hardware: General CLEAR the DTCs. REPEAT the self-test. If DTC
Checksum Failure U2014:41 is retrieved again, INSTALL a new ACM .
REFER to Audio Control Module (ACM) â MKZ in this
section. REPEAT the self-test.
Memory Failure U2014:42 is retrieved again, INSTALL a new ACM .
REFER to Audio Control Module (ACM) â MKZ in this
U2014:96 Control Module Hardware: GO to Pinpoint Test I .
Component Internal Failure
U201A:51 Control Module Main Calibration REFER to Section 418-01 .
Data: Not Programmed
U2100:00 Initial Configuration Not Complete: REFER to Section 418-01 .
U2101:00 Control Module Configuration REFER to Section 418-01 .
Incompatible: No Sub Type
Information
U3003:16 Battery Voltage: Circuit Voltage GO to Pinpoint Test AO .
Below Threshold
U3003:17 GO to Pinpoint Test AP .

Battery Voltage: Circuit Voltage

Above Threshold
Audio Front Control Module (ACM) DTC Chart â Navigation

B119F:01 GPS Antenna: General GO to Pinpoint Test W .
Electrical Failure
B119F:13 GPS Antenna: Circuit Open GO to Pinpoint Test W .
B11BA:1C Steering Wheel Audio Switch GO to Pinpoint Test Q .
Pack: Circuit Voltage out of
Range
B11BA:63 Steering Wheel Audio Switch GO to Pinpoint Test Q .
Pack: Circuit / Component
Protection Time-Out
B1201:1C Steering Wheel Audio Switch GO to Pinpoint Test Q .
Pack 2: Circuit Voltage out of
Range
B1201:63 Steering Wheel Audio Switch GO to Pinpoint Test Q .
Pack 2: Circuit / Component
Protection Time-Out
B121C:01 Hard Drive: General Electrical CLEAR the DTCs. REPEAT the self-test. If DTC B121C:01 is
Failure retrieved again, INSTALL a new Audio Front Control Module
(ACM). REFER to Audio Control Module (ACM) â Fusion
or Audio Control Module (ACM) â MKZ in this section.
Failure

Failure

Failure

Failure


Failure

Failure

B1A07:01 Speaker #7: General Electrical GO to Pinpoint Test Y .
Failure
B1A56:21 Antenna: Signal Amplitude GO to Pinpoint Test A .
â © Minimum
B1A89:01 Satellite Antenna: General GO to Pinpoint Test B .
Electrical Failure
B1A89:13 Satellite Antenna: Circuit Open GO to Pinpoint Test B .
B1D19:49 Compact Disc Unit: Internal CLEAR the DTCs. REPEAT the self-test. If DTC B1D19:49 is
Electronic Failure retrieved again, INSTALL a new Audio Front Control Module
(ACM). REFER to Audio Control Module (ACM) â Fusion
or Audio Control Module (ACM) â MKZ in this section.
B1D19:4B Compact Disc Unit: Over The ACM was over-temperature. This may occur during
Temperature extended use. Audio operation can resume after the ACM cools.
CLEAR the DTCs. This is normal operation.
B1D79:01 Microphone Input: General GO to Pinpoint Test V .
Electrical Failure
U0140:00 Lost Communication With GO to Pinpoint Test AE .
Body Control Module: No Sub
Type Information
Information
U0159:00 Lost Communication With GO to Pinpoint Test U .
Parking Assist Control Module
"A": No Sub Type Information
U0162:00 Lost Communication With GO to Pinpoint Test M .
Navigation Display Module: No
U0164:00 Lost Communication With GO to Pinpoint Test AH .
HVAC Control Module: No
Telephone Control Module: No
U0238:00 GO to Pinpoint Test AL .

Lost Communication With

Digital Audio Control Module
"D": No Sub Type Information
U0256:00 Lost Communication With GO to Pinpoint Test AM .
Front Controls Interface
Module: No Sub Type
Information
U2014:09 Control Module Hardware: GO to Pinpoint Test X .
Component Failure
U2014:41 Control Module Hardware: CLEAR the DTCs. REPEAT the self-test. If DTC U2014:41 is
General Checksum Failure retrieved again, INSTALL a new ACM . REFER to Audio
Control Module (ACM) â Fusion or Audio Control Module
(ACM) â MKZ in this section. REPEAT the self-test.
U2014:96 Control Module Hardware: GO to Pinpoint Test I .
Component Internal Failure
U201A:51 Control Module Main REFER to Section 418-01 .
Calibration Data: Not
Programmed
U2100:00 Initial Configuration Not REFER to Section 418-01 .
Information
Information
U3003:16 Battery Voltage: Circuit GO to Pinpoint Test AO .
U3003:17 Battery Voltage: Circuit GO to Pinpoint Test AP .
Audio Digital Signal Processing (DSP) Module DTC Chart â SonyÂ® Sound

B1A01:01 Speaker #1: General Electrical Failure GO to Pinpoint Test E .
B1A01:11 Speaker #1: Circuit Short to Ground GO to Pinpoint Test E .
B1A01:12 Speaker #1: Circuit Short to Battery GO to Pinpoint Test E .
B1A01:13 Speaker #1: Circuit Open GO to Pinpoint Test E .


B1A09:02 Speaker #9: General Signal Failure GO to Pinpoint Test E .
Information
U0155:00 Lost Communication With Instrument GO to Pinpoint Test AG .
Panel Cluster ( IPC ) Control Module:
U0184:00 Lost Communication With Radio: No GO to Pinpoint Test AJ .
U0197:00 Lost Communication With Telephone GO to Pinpoint Test AK .
Information
Electrical Failure U2014:01 is retrieved again, INSTALL a new audio
Digital Signal Processing (DSP) module. REFER to
Audio Digital Signal Processing (DSP) Module in
this section. REPEAT the self-test.
U2014:41

Control Module Hardware: General CLEAR the DTCs. REPEAT the self-test. If DTC
Checksum Failure U2014:41 is retrieved again, INSTALL a new audio
Digital Signal Processing (DSP) module. REFER to
Audio Digital Signal Processing (DSP) Module in
this section. REPEAT the self-test.
U2100:00 Initial Configuration Not Complete: No REFER to Section 418-01 .
Information
U3003:16 Battery Voltage: Circuit Voltage GO to Pinpoint Test AS .
Below Threshold
U3003:17 Battery Voltage: Circuit Voltage GO to Pinpoint Test AT .
Above Threshold
Audio Digital Signal Processing (DSP) Module DTC Chart â THXÂ® Sound

B1A01:11 Speaker #1: Circuit Short to GO to Pinpoint Test F .
Ground
Battery
B1A01:13 Speaker #1: Circuit Open GO to Pinpoint Test F .
Ground
Battery
Ground
Battery
Ground
Battery
Ground


Battery
Ground
Battery
Ground
Battery
Ground
Battery
Ground
Battery
Ground
Battery
Ground
Battery
Ground
Battery
Information
Information
U0184:00 Lost Communication With Radio: GO to Pinpoint Test AJ .
U0197:00 GO to Pinpoint Test AK .

Lost Communication With

General Checksum Failure retrieved again, INSTALL a new audio Digital Signal
Processing (DSP) module. REFER to Audio Digital Signal
Processing (DSP) Module in this section. REPEAT the
self-test.
General Memory Failure retrieved again, INSTALL a new audio DSP module. REFER
to Audio Digital Signal Processing (DSP) Module in this
U2014:4B Control Module Hardware: Over The audio DSP module was over-temperature. This may occur
Temperature during extended use. Audio operation can resume after the
audio DSP module cools. CLEAR the DTCs. This is normal
operation.
Component Internal Failure retrieved again, INSTALL a new audio DSP module. REFER
to Audio Digital Signal Processing (DSP) Module in this
U2100:00 Initial Configuration Not REFER to Section 418-01 .
Information
Information
U3003:16 Battery Voltage: Circuit Voltage GO to Pinpoint Test AS .
Below Threshold
U3003:17 Battery Voltage: Circuit Voltage GO to Pinpoint Test AT .
Above Threshold
Accessory Protocol Interface Module (APIM) DTC Chart

B1201:1C Steering Wheel Audio Switch Pack 2: GO to Pinpoint Test Q .
Circuit Voltage Out of Range
B1201:63 Steering Wheel Audio Switch Pack 2: GO to Pinpoint Test Q .
Circuit / Component Protection
Time-Out
B1252:04 USB Port: System Internal Failure GO to Pinpoint Test AB .
B1252:11 USB Port: Circuit Short to Ground GO to Pinpoint Test AB .

B1A16:01 Microphone Input Circuit: General GO to Pinpoint Test V .

Electrical Failure
U0100:00 Lost Communication With ECM GO to Pinpoint Test AD .
/PCM "A": No Sub Type Information
Information
U0151:00 Lost Communication With Restraints GO to Pinpoint Test AF .
Information
U0155:00 Lost Communication With Instrument GO to Pinpoint Test AG .
Panel Cluster ( IPC ) Control Module:
U016A:00 Lost Communication With Global GO to Pinpoint Test AI .
Positioning System Module: No Sub
Type Information
U0184:00 Lost Communication With Radio: No GO to Pinpoint Test AJ .
U0255:00 Lost Communication With Front GO to Pinpoint Test AN .
Display Interface Module: No Sub
Type Information
U0256:00 Lost Communication With Front GO to Pinpoint Test AM .
Controls Interface Module: No Sub
Type Information
U0422:00 Invalid Data Received From Body RETRIEVE and FOLLOW other DTCs present in the
Control Module: No Sub Type Accessory Protocol Interface Module (APIM) or Smart
Information Junction Box (SJB).
U0423:00 Invalid Data Received From RETRIEVE and FOLLOW other DTCs present in the
Instrument Panel Control Module: No APIM or Instrument Panel Cluster (IPC).
U046B:00 Invalid Data Received From Global RETRIEVE and FOLLOW other DTCs present in the
Positioning System Module: No Sub APIM or Global Positioning System Module (GPSM).
Type Information
U0485:00 Invalid Data Received From Radio: RETRIEVE and FOLLOW other DTCs present in the
No Sub Type Information APIM or Audio Front Control Module (ACM).
U3000:04 Control Module: System Internal GO to Pinpoint Test Z .
Failure
U3000:41 Control Module: General Checksum CLEAR the DTCs. REPEAT the self-test. If DTC
Failure U3000:41 is still present, INSTALL a new APIM .
REFER to Accessory Protocol Interface Module (APIM)
in this section. REPEAT the self-test.
U3000:42 Control Module: General Memory CLEAR the DTCs. REPEAT the self-test. If DTC
Failure U3000:42 is still present, INSTALL a new APIM .
REFER to Accessory Protocol Interface Module (APIM)
in this section. REPEAT the self-test.
U3000:88 Control Module: Bus Off REFER to Section 418-00 .

U3003:16 Battery Voltage: Circuit Voltage GO to Pinpoint Test AQ .

Below Threshold
U3003:17 Battery Voltage: Circuit Voltage GO to Pinpoint Test AR .
Above Threshold
Front Controls Interface Module (FCIM) DTC Chart â Fusion Without Navigation

B1318 Battery Voltage Low GO to Pinpoint Test AU .
B1342 ECU is Faulted CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is still
present, INSTALL a new Front Controls Interface Module
(FCIM). REFER to Front Controls Interface Module (FCIM)
â Fusion in this section. REPEAT the self-test.
B2924 Audio Button Stuck GO to Pinpoint Test J .
U0140 Lost Communication With Body GO to Pinpoint Test AE .
Control Module ( GEM )
U0164 Lost Communication With GO to Pinpoint Test AH .
HVAC Control Module ( EATC
)
U0184 Lost Communication With GO to Pinpoint Test AJ .
Radio ( ACM )
U2051 One or More Calibration Files REFER to Section 418-01 .
Missing/Corrupt
Front Controls Interface Module (FCIM) DTC Chart â MKZ Without Navigation, All Vehicles
With Navigation

Body Control Module: No Sub
Type Information
U0184:00 Lost Communication With GO to Pinpoint Test AJ .
Radio: No Sub Type
Information
U2013:63 Switch Pack: Circuit / GO to Pinpoint Test J .
Component Protection
Time-Out
U2014:41

Control Module Hardware: CLEAR the DTCs. REPEAT the self-test. If DTC U2014:41 is
General Checksum Failure still present, INSTALL a new Front Controls Interface Module
(FCIM). REFER to Front Controls Interface Module (FCIM) â
MKZ in this section. REPEAT the self-test.
General Memory Failure still present, INSTALL a new FCIM . REFER to Front Controls
Interface Module (FCIM) â MKZ in this section. REPEAT the
self-test.
U201A:51 Control Module Main REFER to Section 418-01 .
Calibration Data: Not
Programmed
U3003:16 Battery Voltage: Circuit GO to Pinpoint Test AU .
U3003:17 Battery Voltage: Circuit GO to Pinpoint Test AV .
Front Display Interface Module (FDIM) DTC Chart â Vehicles Without Navigation

B1318 Battery Voltage Low GO to Pinpoint Test AW .
B1342 ECU is Faulted CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is still
present, INSTALL a new Front Display Interface Module (FDIM).
REFER to Front Display Interface Module (FDIM) â Fusion or
Front Display Interface Module (FDIM) â MKZ in this section.
B2477 Module Configuration REFER to Section 418-01 .
Failure
B2924 Audio Button Stuck GO to Pinpoint Test AZ .
U0140 Lost Communication With GO to Pinpoint Test AE .
Body Control Module ( GEM
)
U0155 Lost Communication With GO to Pinpoint Test AG .
Instrument Panel Cluster ( IC
) Control Module
U0164 Lost Communication With GO to Pinpoint Test AH .
HVAC Control Module (
EATC )
U0184 Lost Communication With GO to Pinpoint Test AJ .
Radio ( ACM )
U0197 Lost Communication With GO to Pinpoint Test AK .
Telephone Control Module
U0238 Lost Communication With GO to Pinpoint Test AL .
Digital Audio Control
Module "D" ( DSP )
U2051 REFER to Section 418-01 .

One or More Calibration

Files Missing/Corrupt
Global Positioning System Module (GPSM) DTC Chart

Information
Information
U0184:00 Lost Communication With Radio: GO to Pinpoint Test AJ .
U0422:00 Invalid Data Received From Body RETRIEVE and FOLLOW diagnostics for other DTCs present
Control Module: No Sub Type in the Global Positioning System Module (GPSM) and
Information Restraints Control Module (RCM).
U0423:00 Invalid Data Received From Body RETRIEVE and FOLLOW diagnostics for other DTCs present
Control Module: No Sub Type in the GPSM and Instrument Panel Cluster (IPC).
Information
U3000:09 Control Module: Component CLEAR the DTCs. REPEAT the self-test. If DTC U3000:09 is
Failure still present, INSTALL a new GPSM . REFER to Global
Positioning System Module (GPSM) â Fusion or Global
Positioning System Module (GPSM) â MKZ in this section.
U3000:41 Control Module: General CLEAR the DTCs. REPEAT the self-test. If DTC U3000:41 is
Checksum Failure still present, INSTALL a new GPSM . REFER to Global
U3000:42 Control Module: General Memory CLEAR the DTCs. REPEAT the self-test. If DTC U3000:42 is
Failure still present, INSTALL a new GPSM . REFER to Global
U3003:16 Battery Voltage: Circuit Voltage GO to Pinpoint Test AX .
Below Threshold
U3003:17 Battery Voltage: Circuit Voltage GO to Pinpoint Test AY .
Above Threshold

Symptom Chart â General Audio System
General Audio System
Symptom Chart â Sound Quality
Sound Quality
Symptom Chart â Satellite Radio
Satellite Radio
Symptom Chart â Navigation
Navigation
Symptom Chart â SYNCÂ® System
SYNCÂ® System
Pinpoint Tests
Pinpoint Test A: Poor Reception â AM/FM
Refer to Wiring Diagrams Cell 130 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Audio System/Navigation
Normal Operation â Fusion
The AM/FM antenna receives AM and FM radio waves and transmits them to the Audio Front Control
Module (ACM) through the AM/FM antenna cable. The ACM powers the AM/FM antenna in order to
amplify the AM signal.
MKZ
The AM/FM radio antenna, integral to the rear window, receives AM and FM radio waves. The antenna
module sends the radio waves to the ACM through the AM/FM antenna cable.
Normal Operation â Fusion 5723

All Vehicles
The noise suppression equipment reduces engine ignition and electrical systems interference transmitted
through the speakers.
The RDS function allows the vehicle operator to choose which genre (category) of music to listen to. When
the SCAN button is pressed, the ACM only stops at channels falling within the selected category. If no
channel in the selected category is found, the ACM continues to scan without stopping. This may appear to be
a reception issue, but it is actually due to the customer setting.
• DTC B1A56:21 (Antenna: Signal Amplitude â © Minimum) â sets when the signal strength is less
than the pre-configured threshold value during the self-test.
• DTC B2103 (Antenna Not Connected) â sets when the signal strength is less than the
pre-configured threshold value during the self-test. This DTC applies to base and mid-level sound
only.
• No channel found in the selected category

• AM/FM antenna
• AM/FM antenna cable
• Charging system
• Ignition system
• Noise suppression equipment
• Antenna module (MKZ only)
• ACM
PINPOINT TEST A: POOR RECEPTION â AM/FM

A1 CHECK THE RDS SETTING
Yes
• Turn the RDS function off. Refer to the Owner's The system is operating correctly at
Literature. this time. The concern was a result of
• Scan for a good channel. no channel being found in the selected
• Does the audio system find a good channel with category.
normal reception?
No
GO to A2 .
A2 CHECK THE AUDIO SYSTEM RECEPTION
Yes
• Check the audio system reception with the engine GO to A3 .
running, and with the engine off.
• Does the poor reception only occur with the engine No
running? GO to A7 .
A3 CHECK THE NOISE SUPPRESSION EQUIPMENT
All Vehicles 5724

• Check the engine ground strap for security, cleanliness, Yes

and metal-to-metal contact. GO to A4 .
• Are the connections clean, secure, and in
metal-to-metal contact? No
CLEAN and SECURE the connections,
or INSTALL a new engine ground
strap as needed. TEST the system for
normal operation.
A4 CHECK THE RADIO INTERFERENCE
CAPACITOR
Yes
• Install a new radio interference capacitor. The cause of the concern was an
• Start the vehicle. inoperative radio interference
• Operate the audio system in radio tuner (AM/FM) capacitor. The system is now operating
mode. correctly.
• Is the reception OK?
No
GO to A5 .
A5 CHECK THE GENERATOR
Yes
• Disconnect: Generator C102a . Section 414-00 . TEST the system for
• Start the engine. normal operation.
• Operate the audio system in radio tuner (AM/FM)
mode. No
• Is the reception OK? GO to A6 .
A6 CHECK THE IGNITION CIRCUITS
Yes
• Ignition OFF. USE a jumper cable to ground various
• Connect: Generator C102a . parts of the vehicle to the frame (for
• Check the ignition circuits for correct routing, example: engine, fenders, quarter
grounding, and integrity of the connections. panels, stone deflectors, air cleaner,
• Are the ignition components OK? body sheet metal). When the noise is
eliminated, PROVIDE a permanent
ground where necessary. TEST the
No
REPAIR the ignition system as
necessary. TEST the system for normal
operation.
A7 CHECK THE AM/FM ANTENNA ENABLE CIRCUIT
Yes
• Ignition OFF. For Fusion GO to A11 .
• Disconnect: AM/FM Antenna C9021 (Fusion) .
• Disconnect: Antenna Module C4194a (MKZ) . For MKZ, GO to A9 .
mode. No
• For Fusion measure the voltage between the AM/FM GO to A8 .
antenna C9021-1, circuit CME44 (BU), harness side
and ground.
PINPOINT TEST A: POOR RECEPTION â AM/FM 5725

• For MKZ, measure the voltage between the antenna

module C4194a-1, circuit CME44 (YE/GN), harness
side and ground.

A8 CHECK THE AM/FM ANTENNA ENABLE CIRCUIT
FOR AN OPEN OR SHORT TO GROUND
Yes
• Disconnect: ACM C240a .
• For Fusion, measure the resistance between the ACM No
C240a-5, circuit CME44 (YE/GN), harness side and the REPAIR the circuit. TEST the system
AM/FM antenna C9021-1, circuit CME44 (BU), for normal operation.
harness side; and between the ACM C240a-5, circuit
CME44 (YE/GN), harness side and ground.
• For MKZ, measure the resistance between the ACM

C240a-5, circuit CME44 (YE/GN), harness side and the
antenna module C4194a-1, circuit CME44 (YE/GN),
harness side; and between the ACM C240a-5, circuit
CME44 (YE/GN), harness side and ground.

• Is the resistance less than 5 ohms between the ACM

and the AM/FM antenna (or antenna module), and
greater than 10,000 ohms between the ACM and
ground?
A9 CHECK THE ANTENNA GRID
Yes
• Inspect the antenna grid closely for signs of damage.
• Is the antenna grid OK? No
REPAIR the antenna grid as necessary.
REFER to Section 501-11 . TEST the
A10 ISOLATE THE ANTENNA MODULE
Yes
• Ignition OFF. The concern was caused by an
• Install a new antenna module. Refer to Antenna Module inoperative antenna module. The
in this section. system is now operating correctly.
mode. No
A11 ISOLATE THE AM/FM ANTENNA
Yes
• Ignition OFF. The concern was caused by an
• Install a new AM/FM antenna. Refer to Antenna â inoperative AM/FM antenna. The
AM/FM in this section. system is now operating correctly.
mode. No
A12 ISOLATE THE AM/FM ANTENNA CABLE
Yes
• Ignition OFF. INSTALL a new AM/FM antenna
• Substitute each AM/FM antenna cable by routing a new cable for the inoperative cable. REFER
component. Do not remove the original antenna cable at to Antenna Cable â AM/FM in this
this time. section. TEST the system for normal
• Operate the audio system in radio tuner (AM/FM) operation.
mode.
• Is the reception OK? No
GO to A13 .
A13 CHECK FOR CORRECT ACM OPERATION
Yes
• Ignition OFF. INSTALL a new ACM . REFER to
• Disconnect all the ACM connectors. Audio Control Module (ACM) â
• Check for: Fusion or Audio Control Module
♦ corrosion (ACM) â MKZ in this section.
♦ damaged pins TEST the system for normal operation.

♦ pushed-out pins
• Connect all the ACM connectors and make sure they No
seat correctly. The system is operating correctly at
• Operate the system and determine if the concern is still this time. The concern may have been
Pinpoint Test B: Poor Reception/Poor Sound Quality/No Sound â Satellite Radio
Normal Operation
Digital signals are received by the satellite radio antenna and sent to the Audio Front Control Module (ACM),
as the satellite radio receiver is built-in to the ACM .
A short to ground in the satellite radio antenna typically has no effect on the antenna signal. However, an open
in the antenna circuit results in no sound from the satellite radio system. A short to voltage in the antenna
circuit can have varying effects on the system.
Obstructions to the antenna line of sight can affect reception, but this is considered normal operation. Possible
obstructions include hills, tall buildings, tunnels, and being parked inside a garage. Be sure the vehicle is in a
clear area, free of obstructions, before testing satellite radio reception.

Sets when an open or high resistance is detected in the satellite
• B1031 â SDARS Satellite antenna circuit. This DTC can be either continuous or
Antenna Open on-demand.
Sets when a short to ground is detected in the satellite antenna
• B1032 â SDARS Satellite circuit. This DTC can be either continuous or on-demand.
Antenna Short
May set when any fault is detected in the satellite radio antenna
• B1A89:01 â Satellite Antenna: circuit. This DTC can be either continuous or on-demand.
General Electrical Failure
Sets when an open is detected in the satellite radio antenna
• B1A89:13 â Satellite Antenna: circuit. This DTC can be either continuous or on-demand.
Circuit Open
• Obstructions to the antenna line of sight

• No channel found in the selected category
• Satellite radio antenna
• ACM

PINPOINT TEST B: POOR RECEPTION/POOR SOUND QUALITY/NO SOUND â SATELLITE RADIO

B1 CHECK THE RECEPTION AND CATEGORY
FILTER SETTING
Yes
• Turn the category filter function off. For The system is operating correctly at this time.
additional information, refer to the Owner's The concern was a result of no channel being
Literature. found in the selected category.
• Drive the vehicle to an open location, free of
obstacles. No
• Scan for a good channel. GO to B2 .
• Does the satellite audio system find a good
channel with normal reception?
B2 CHECK THE SATELLITE SIGNAL PID
(SAT_SIG_STR)
Yes
• Enter the following diagnostic mode on the scan GO to B3 .
tool: ACM DataLogger .
• Monitor the ACM PID (SAT_SIG_STR). No
• Does the PID indicate "No Signal"? GO to Pinpoint Test I .
B3 CHECK THE SATELLITE RADIO ANTENNA
CABLE RESISTANCE
Yes
• Disconnect: Satellite Radio Antenna Connection
At ACM . No
• Disconnect: Satellite Radio Antenna Cable INSTALL a new front or rear satellite radio
In-Line Connection At RH Kick Panel . antenna cable. REFER to Antenna Cable â
• Disconnect: Satellite Radio Antenna Connection Satellite Radio in this section. CLEAR any
At Satellite Radio Antenna . DTCs present. TEST the system for normal
• Measure the resistance of the front satellite radio operation.
antenna cable core between the ACM and the
satellite radio antenna in-line connection; and
between the front satellite radio antenna cable
core and shield.
• Measure the resistance of the rear satellite radio
antenna cable core between the satellite radio
antenna and the satellite radio antenna in-line
connection; and between the rear satellite radio
antenna cable core and shield.
• Is the resistance of each satellite radio antenna
cable core less than 2 ohms, and the resistance
between the core and shield of each satellite
radio antenna cable greater than 10,000
ohms?
B4 ISOLATE THE SATELLITE RADIO
ANTENNA
Yes
PINPOINT TEST B: POOR RECEPTION/POOR SOUND QUALITY/NO SOUND â SATELLITE

5729
RADIO
• Install a new satellite radio antenna. Refer to The concern was caused by an inoperative
Antenna â Satellite Radio in this section. satellite radio antenna. The system is
• Operate the audio system in satellite radio mode. operating correctly at this time. CLEAR any
• Is the reception OK? DTCs present.
No
GO to B5 .
B5 CHECK FOR CORRECT ACM MODULE
OPERATION
Yes
• Ignition OFF. INSTALL a new ACM module. REFER to in
• Disconnect all the ACM module connectors. Audio Control Module (ACM) â Fusion or
• Check for: Audio Control Module (ACM) â MKZ this
♦ pushed-out pins
• Connect all the ACM module connectors and No
make sure they seat correctly. The system is operating correctly at this time.
is still present. or corroded connector.
Pinpoint Test C: No Sound From One Or More Speakers (Not All Speakers) â Base, Mid-Level
Sound
Normal Operation
The Audio Front Control Module (ACM) directs audio signals to the speakers in the form of an AC voltage.
The ACM provides internal circuit protection for shorts to ground or shorts to voltage.
A short to ground or short to voltage in the circuitry to one of the speakers can cause multiple speakers to lose
sound due to the built-in overload protection feature of the ACM . In this case, a speaker fault DTC sets, and
this pinpoint test should be followed to isolate the damaged circuit.
It should also be noted that when the ACM activates the built-in overload protection, DTC B1342 may also be
set. The circuit failure must be repaired before DTC B1342 can be cleared.
The speaker walk test can be used to isolate a concern with a particular speaker. This can reduce the
diagnostic steps necessary to isolate the concern. To carry out the speaker walk test, refer to Audio Control
Module (ACM) Self-Diagnostic Mode in this section.
• DTC B2965 (Audio System Speaker Circuit Fault) â sets when a short to ground, short to voltage,
or open is detected on any of the speaker circuits.

• Speaker
• ACM

PINPOINT TEST C: NO SOUND FROM ONE OR MORE SPEAKERS (NOT ALL SPEAKERS) â BASE, MID-LEVEL
SOUND

C1 DETERMINE THE INOPERATIVE SPEAKER(S)
Yes
• Carry out the speaker walk test. Refer to Audio Control GO to C2 .
• Is the concern only with a tweeter speaker? No
GO to C5 .
C2 CHECK FOR VOLTAGE TO THE SUSPECT
TWEETER SPEAKER
Yes
• Ignition OFF. INSTALL a new speaker for the
• Disconnect: Suspect Tweeter Speaker . suspect tweeter speaker. REFER to
• Operate the audio system in radio tuner (AM/FM) Speaker â Door in this section.
mode. CLEAR any DTCs present. TEST the
• Measure the AC voltage between the suspect tweeter system for normal operation.
speaker pin 1 and pin 2, harness side as follows:
No
GO to C3 .
Suspect Positive Meter Negative Meter

Speaker Lead Lead
LH tweeter C569-1 C569-2
VME07 (WH) RME07 (WH/BN)

RH tweeter C613-1 C613-2
VME11 (VT/OG) RME11 (YE/OG)
• Is a fluctuating AC voltage present?

C3 CHECK THE CIRCUITS TO THE SUSPECT
TWEETER SPEAKER FOR A SHORT TO VOLTAGE
PINPOINT TEST C: NO SOUND FROM ONE OR MORE SPEAKERS (NOT ALL SPEAKERS) â5731BASE, M

• Disconnect: LF Door Speaker C592b (LH Speaker REPAIR the circuit in question.
Concern) or RF Door Speaker C692b (RH Speaker CLEAR any DTCs present. TEST the
Concern) . system for normal operation.
• Ignition ON.
• Measure the voltage between the suspect tweeter No
speaker, harness side and ground as follows: GO to C4 .
Negative
Suspect Tweeter Positive Meter Meter
Speaker Lead Lead
LH tweeter C569-1 Ground
VME07 (WH)
RME07 (WH/GN)
RH tweeter C613-1 Ground
VME11 (VT/OG)
RME11 (YE/OG)

TWEETER SPEAKER FOR AN OPEN OR SHORT TO
GROUND
Yes
• Ignition OFF. INSTALL a new door speaker. REFER
• Measure the resistance between the suspect tweeter to Speaker â Door in this section.
speaker, harness side and the door speaker, harness CLEAR any DTCs present. TEST the
side; and between the suspect tweeter speaker, harness system for normal operation.
side and ground as follows:
No
CLEAR any DTCs present. TEST the
Suspect
Tweeter Positive Negative
Speaker Meter Lead Meter Lead Circuit
LH tweeter C569-1 C592b-1, VME07

then ground (WH) or
VME08
(GN/OG)
LH tweeter C569-2 C592b-2, RME07
then ground (WH/GN)
or RME08
(GY/OG)
RH tweeter C613-1 C692b-1, VME11
then ground (VT/OG)
RH tweeter C613-2 C692b-2, RME11
then ground (YE/OG)
• Is the resistance less than 5 ohms between the

suspect tweeter speaker and the door speaker, and
greater than 10,000 ohms between the suspect
tweeter speaker and ground?
C5 CHECK THE AUDIO SIGNALS TO THE SUSPECT
SPEAKER
Yes
• Disconnect: Suspect Speaker . suspect speaker. REFER to Speaker
• Operate the audio system in radio tuner (AM/FM) â Door in this section. CLEAR any
mode. DTCs present. TEST the system for
• Measure the AC voltage between the suspect speaker normal operation.
pins, harness side as follows:
No
GO to C6 .

Speaker Lead Lead
LF door C523-1 or C523-2 or C592a-2
C592a-1
RME07 (WH/BN)
VME07 (WH)
RF door C612-1 or C612-2 or C692a-2
C692a-1
RME10 (WH/OG)
VME10 (WH/VT)
LR door C702-1 C702-2
VME09 (WH/GN) RME09 (BN/YE)
RR door C802-1 C802-2
VME12 (BN/WH) RME12 (BN/BU)

SPEAKER FOR A SHORT TO VOLTAGE
Yes
• Disconnect: ACM C240a . CLEAR any DTCs present. TEST the
• Measure the voltage between the suspect speaker,
harness side and ground as follows: No
GO to C7 .

Speaker Lead Lead
LF door C523-1 or C523-2 or C592a-2
C592a-1
RME07 (WH/BN)
VME07 (WH)
RF door C612-1 or C612-2 or C692a-1
C692a-1
RME10 (WH/OG)
VME10 (WH/VT)
LR door C702-1 C702-2

RR door C802-1 C802-2
C7 CHECK THE SPEAKER CIRCUITS FOR AN OPEN

OR SHORT TO GROUND
Yes
• Measure the resistance between suspect speaker,
harness side and the ACM , harness side; and between No
the suspect speaker, harness side and ground as follows: REPAIR the circuit in question.
CLEAR any DTCs present. TEST the
Suspect Positive Meter Negative

Speaker Lead Meter Lead Circuit
LH front C523-1 or C240a-8 VME07
C592a-1, then (WH)
ground
C523-2 or C240a-21 RME07
C592a-2, then (WH/BN)
ground
RH front C612-1 or C240a-11 VME10
C692a-1, then (WH/VT)
ground
C612-2 or C240a-12 RME10
C692a-2, then (WH/OG)
ground
LH rear C702-1, then C240a-9 VME09
ground (WH/GN)
C702-2, then C240a-22 RME09
ground (BN/YE)
RH rear C802-1, then C240a-10 VME12
ground (BN/WH)
C802-2, then C240a-23 RME12
ground (BN/BU)
• Are the resistances less than 5 ohms between the

ACM and the suspect speaker, and greater than
10,000 ohms between the ACM and ground?
C8 CHECK FOR CORRECT ACM OPERATION
Yes
• Disconnect all the ACM connectors. INSTALL a new ACM . REFER to
• Check for: Audio Control Module (ACM) â
♦ corrosion Fusion or Audio Control Module
♦ damaged pins (ACM) â MKZ in this section. TEST
♦ pushed-out pins the system for normal operation.

• Connect all the ACM connectors and make sure they
seat correctly. No
• Operate the system and determine if the concern is still The system is operating correctly at this
present. time. The concern may have been
connector. CLEAR any DTC present.
Pinpoint Test D: No Sound From One Or More Speakers (Not All Speakers) â Premium Sound
Normal Operation
The Audio Front Control Module (ACM) directs audio signals to the audio amplifier and to the subwoofer
amplifier in the form of an AC voltage. The amplifiers boost the audio signals and send them to the speakers.
The ACM provides internal circuit protection for shorts to ground or shorts to voltage.
A short to ground or short to voltage in the circuitry to one of the speakers may cause multiple speakers to
lose sound due to the built-in overload protection feature of the ACM . In this case, a speaker fault DTC sets,
and this pinpoint test should be followed to isolate the damaged circuit.
To enable the amplifiers, the ACM sends voltage through individual enable/clip circuits. The circuits act as
both an output (to enable the amplifier) and an input (to detect an overload condition). The voltage sent by the
ACM passes through a variable resistor in each amplifier, then to ground. As the amplifier reaches maximum
output, the resistance in the variable resistor decreases. This decreases the voltage drop, resulting in the ACM
detecting a higher voltage on the enable/clip circuit. When the voltage reaches the clip threshold, the ACM
clips the audio output signal to the amplifier (heard as distortion), in order to prevent damage to the amplifier
and speakers.
The enable/clip status is based on the following voltages, as detected by the ACM :
• Less than 0.4 volt: amplifier disabled

• Between 3.8 and 6.7 volts (nominal): amplifier enabled
• Greater than 8.5 volts: amplifier clipped
An open in the enable/clip circuit causes the speakers powered by that particular amplifier to produce no
sound because the enable signal does not reach the audio amplifier. A short to ground or short to voltage can
cause severe distortion to be heard in the speakers.
Root DTC Failure-Type

Description Codes Fault Trigger Conditions
01, 11, 12, 13 Sets when a fault is detected in the LF speaker circuits. This DTC can
• B1A01 be continuous or on-demand.
â

Speaker #1
01, 11, 12, 13 Sets when a fault is detected in the RF speaker circuits. This DTC can
â
Speaker #2
01, 11, 12, 13 Sets when a fault is detected in the RR speaker circuits. This DTC can
â
Speaker #3
01, 11, 12, 13 Sets when a fault is detected in the LR speaker circuits. This DTC can
â
Speaker #4
01, 02 Sets when a fault is detected in the subwoofer speaker circuits. This
• B1A05 DTC can be continuous or on-demand.
â
Speaker #5
01, 02 Sets when a fault is detected in the instrument panel speaker circuits.
• B1A06 This DTC can be continuous or on-demand.
â
Speaker #6
• Fuse
• Speaker
• Audio amplifier
• Subwoofer amplifier
• ACM
PINPOINT TEST D: NO SOUND FROM ONE OR MORE SPEAKERS (NOT ALL SPEAKERS) â PREMIUM SOUND
Section 414-01 .

D1 DETERMINE THE INOPERATIVE SPEAKER(S)
Yes
• Carry out the speaker walk test. Refer to Audio Control GO to D2 .
• Is the concern only with the subwoofer speakers? No
If the concern is only with a
tweeter speaker, GO to D14 .
For all other concerns, GO to
PINPOINT TEST D: NO SOUND FROM ONE OR MORE SPEAKERS (NOT ALL SPEAKERS) â5737PREMIU
D17 .
D2 DETERMINE THE INOPERATIVE SUBWOOFER
Yes
• Operate the audio system in radio tuner (AM/FM) mode and GO to D3 .
observe the subwoofer operation.
• Do both of the subwoofers have a concern? No
GO to D11 .
D3 CHECK THE SUBWOOFER AMPLIFIER VOLTAGE
SUPPLY
Yes
• Disconnect: Subwoofer Amplifier C466a .
• Measure the voltage between the subwoofer amplifier No
C466a-5, circuit SBP38 (BN/RD), harness side and ground. VERIFY the Smart Junction Box
(SJB) fuse 38 (20A) is OK. If
OK, REPAIR the circuit.
CLEAR any DTCs present.
operation. If not OK, REFER to
the Wiring Diagrams Manual to
identify the possible causes of
the circuit short.

D4 CHECK THE SUBWOOFER AMPLIFIER GROUND
CIRCUIT FOR CONTINUITY
Yes
• Disconnect: Negative Battery Cable . GO to D5 .
• Measure the resistance between the subwoofer amplifier
C466a-2, circuit GD148 (BK/YE), harness side and ground. No
REPAIR the circuit. CLEAR any
DTCs present. TEST the system

D5 CHECK THE SUBWOOFER AMPLIFIER ENABLE
CIRCUIT FOR CORRECT VOLTAGE
Yes
• Connect: Negative Battery Cable . GO to D8 .
• Operate the audio system in radio tuner (AM/FM) mode.
C466a-1, circuit SME23 (VT/RD), harness side and ground. GO to D6 .

Yes
• Ignition OFF. REPAIR the circuit. TEST the
• Disconnect: ACM C240d . system for normal operation.
• Ignition ON.
C466a-1, circuit SME23 (VT/RD), harness side and ground. GO to D7 .

CIRCUIT FOR AN OPEN OR SHORT TO GROUND
Yes
• Measure the voltage between the subwoofer amplifier
C466a-1, circuit SME23 (VT/RD), harness side and the ACM No
C240d-4, circuit SME23 (VT/RD), harness side and ground; REPAIR the circuit. TEST the
and between the subwoofer amplifier C466a-1, circuit SME23 system for normal operation.
(VT/RD), harness side and ground.
• Is the resistance less than 5 ohms between the subwoofer

amplifier and the ACM , and greater than 10,000 ohms
between the subwoofer amplifier and ground?
D8 CHECK THE AUDIO SIGNAL TO THE SUBWOOFER
AMPLIFIER
• Operate the audio system in radio tuner (AM/FM) mode. Yes

• Measure the AC voltage between the subwoofer amplifier INSTALL a new subwoofer
C466a-7, circuit VME22 (VT/GN), harness side and the amplifier. REFER to Subwoofer
subwoofer amplifier C466a-8, circuit RME22 (GN/WH), Amplifier in this section.
harness side. CLEAR any DTCs present.
operation.
No
GO to D9 .

D9 CHECK THE AUDIO CIRCUITS TO THE SUBWOOFER
AMPLIFIER FOR A SHORT TO VOLTAGE
Yes
• Measure the voltage between the subwoofer amplifier CLEAR any DTCs present.
C466a-7, circuit VME22 (VT/GN), harness side ground; and TEST the system for normal
between the subwoofer amplifier C466a-8, circuit RME22 operation.
(GN/WH), harness side and ground.
No
GO to D10 .

D10 CHECK THE AUDIO CIRCUITS TO THE SUBWOOFER
AMPLIFIER FOR AN OPEN OR SHORT TO GROUND
Yes
• Measure the resistance between the subwoofer amplifier, GO to D28 .
harness side and the ACM , harness side; and between the
subwoofer amplifier, harness side and ground as follows: No
operation.
Positive Meter Negative Meter
Lead Lead Circuit
C466a-7 C240d-1, then VME22 (VT/GN)
ground
C466a-8 C240d-2, then RME22
ground (GN/WH)
• Is the resistance less than 5 ohms between the subwoofer

between the subwoofer amplifier and ground?
D11 CHECK THE AUDIO SIGNAL TO THE SUSPECT
SUBWOOFER SPEAKER
Yes
• Ignition OFF. INSTALL a new subwoofer
• Disconnect: Suspect Subwoofer Speaker . speaker for the suspect speaker.
• Ignition ON. REFER to Speaker â
• Operate the audio system in radio tuner (AM/FM) mode. Subwoofer in this section. TEST
• Measure the AC voltage between the LH subwoofer speaker the system for normal operation.
C3120-1, circuit VME01 (GN/VT), harness side and the LH
subwoofer speaker C3120-2, circuit RME01 (GY), harness No
side; or between the RH subwoofer speaker C3121-1, circuit GO to D12 .
VME02 (VT), harness side and the RH subwoofer speaker
C3121-2, circuit RME02 (YE), harness side.

D12 CHECK THE AUDIO CIRCUITS TO THE SUSPECT
SUBWOOFER SPEAKER FOR A SHORT TO VOLTAGE
Yes
• Disconnect: Subwoofer Amplifier C466b . TEST the system for normal
• Measure the voltage between the suspect subwoofer speaker,
GO to D13 .
Negative
Suspect Subwoofer Positive Meter Meter
Speaker Lead Lead
LH C3120-1 C3120-2
VME01 (GN/VT) RME01

(GY)
RH
C3121-1 C3121-2
VME02 (VT) RME02

(YE)

D13 CHECK THE AUDIO CIRCUITS TO THE SUSPECT
SUBWOOFER SPEAKER FOR AN OPEN OR SHORT TO
GROUND
Yes
• Ignition OFF. INSTALL a new subwoofer
• Measure the resistance between the suspect subwoofer amplifier. REFER to Subwoofer
speaker, harness side and the subwoofer amplifier, harness Amplifier in this section. TEST
side; and between the suspect subwoofer speaker, harness side the system for normal operation.
and ground as follows:
No
operation.
Suspect
Subwoofer Positive Negative
Subwoofer #1 C3120-1 C466b-1, then VME01
ground (GN/VT)
C3120-2
C466b-2, then RME01
ground (GY)
Subwoofer #2 C3121-1 C466b-3, then VME02
ground (VT)
C3121-2
C466b-4, then RME02
ground (YE)
• Is the resistance less than 5 ohms between the suspect

subwoofer speaker and the subwoofer amplifier, and
greater than 10,000 ohms between the suspect subwoofer
speaker and ground?

D14 CHECK FOR AN AUDIO SIGNAL TO THE SUSPECT
TWEETER SPEAKER
Yes
• Disconnect: Suspect Tweeter Speaker . suspect tweeter speaker. REFER
• Operate the audio system in radio tuner (AM/FM) mode. to Speaker â Door in this
• Measure the AC voltage between the suspect tweeter speaker section. CLEAR any DTCs
pin 1 and pin 2, harness side as follows: present. TEST the system for
normal operation.
No
GO to D15 .
Speaker Lead Lead
VME07 (WH) RME07 (WH/GN)


D15 CHECK THE CIRCUITS TO THE SUSPECT TWEETER
SPEAKER FOR A SHORT TO VOLTAGE
Yes
• Disconnect: LF Door Speaker C592b (LH Speaker Concern) CLEAR any DTCs present.
or RF Door Speaker C692b (RH Speaker Concern) . TEST the system for normal
• Measure the voltage between the suspect tweeter speaker,
GO to D16 .
Suspect Tweeter Positive Meter Negative Meter

Speaker Lead Lead
LH tweeter C569-1 VME07 (WH)
LH tweeter C569-2 RME07 (WH/GN)
RH tweeter C613-1 VME11 (VT/OG)
RH tweeter C613-2 RME11 (YE/OG)

D16 CHECK THE CIRCUITS TO THE SUSPECT TWEETER
SPEAKER FOR AN OPEN OR SHORT TO GROUND
Yes
• Ignition OFF. INSTALL a new door speaker.
• Measure the resistance between the suspect tweeter speaker, REFER to Speaker â Door in
harness side and the door speaker, harness side; and between this section. CLEAR any DTCs
the suspect tweeter speaker, harness side and ground as present. TEST the system for
follows: normal operation.
No
Suspect Positive TEST the system for normal
Tweeter Meter Negative operation.
Speaker Lead Meter Lead Circuit
LH tweeter C569-1 C592b-1, VME07 (WH) or
then ground VME08 (GN/OG)
LH tweeter C569-2 C592b-2, RME07 (WH/GN)
then ground or RME08
(GY/OG)
RH tweeter C613-1 C692b-1, VME11 (VT/OG)
then ground
RH tweeter C613-2 C692b-2, RME11 (YE/OG)
then ground
• Is the resistance less than 5 ohms between the suspect

tweeter speaker and the door speaker, and greater than
10,000 ohms between the suspect tweeter speaker and
ground?
D17 CHECK THE AUDIO SIGNALS TO THE SUSPECT
SPEAKER

• Disconnect: Suspect Speaker . INSTALL a new speaker for the
• Operate the audio system in radio tuner (AM/FM) mode. suspect speaker. REFER to
• Measure the AC voltage between the suspect speaker pins, Speaker â Door in this
harness side as follows: section. CLEAR any DTCs
present. TEST the system for
normal operation.
No
Suspect Positive Meter Negative Meter GO to D18 .
Speaker Lead Lead
LF door C592a-1 C592a-2

RF door C692a-1 C692a-2
VME10 (WH/VT) RME10 (WH/OG)

LR door C702-1 C702-2

RR door C802-1 C802-2

Instrument panel C2363-1 C2363-2
VME06 (GN) RME06 (GY/YE)

D18 CHECK THE AUDIO AMPLIFIER VOLTAGE
Yes
• Disconnect: Audio Amplifier C4208a .
• Measure the voltage between the audio amplifier C4208a-12, No
circuit SBB20 (GN/RD), harness side and ground; and VERIFY the Smart Junction Box
between the audio amplifier C4208a-24, circuit SBB21 (SJB) fuses 20 (20A) and 21 (20)
(GY/RD), harness side and ground. are OK. If OK, REPAIR the
circuit in question. TEST the
system for normal operation. If
not OK, REFER to the Wiring
Diagrams Manual to identify the
possible causes of the circuit
short.

D19 CHECK THE AUDIO AMPLIFIER GROUND CIRCUITS
FOR CONTINUITY
Yes
• Measure the resistance between the audio amplifier No
C4208a-21, circuit GD148 (BK/YE), harness side and ground; REPAIR the circuit in question.
and between the audio amplifier C4208a-22, circuit GD148 TEST the system for normal
(BK/YE), harness side and ground. operation.

D20 CHECK THE AUDIO AMPLIFIER ENABLE CIRCUIT
FOR CORRECT VOLTAGE
Yes
• Connect: Audio Amplifier C4208a .
• Disconnect: Audio Amplifier C4208b . No
• Operate the audio system in radio tuner (AM/FM) mode. GO to D21 .
• Measure the voltage between the audio amplifier C4208b-11,
circuit SME56 (BN), harness side and ground.

FOR A SHORT VOLTAGE

• Connect: ACM C240d . REPAIR the circuit. TEST the
• Measure the voltage between the audio amplifier C4208b-11,
circuit SME56 (BN), harness side and ground. No
GO to D22 .

Yes
• Measure the resistance between the audio amplifier
C4208b-11, circuit SME56 (BN), harness side and the ACM No
C240d-8, circuit SME56 (BN), harness side; and between the REPAIR the circuit. TEST the
audio amplifier C4208b-11, circuit SME56 (BN), harness side system for normal operation.
and ground.
• Is the resistance less than 5 ohms between the audio

between the audio amplifier and ground?
D23 CHECK THE AUDIO SIGNALS TO THE AUDIO
AMPLIFIER
Yes
• Connect: Audio Amplifier C4208a . GO to D24 .
• Disconnect: Audio Amplifier C4208b .
• Ignition ON. No
• Operate the audio system in radio tuner (AM/FM) mode. GO to D26 .
• Measure the AC voltage between the audio amplifier pins,
harness side as follows:

Speaker Lead Lead
LF door
C4208b-2 C4208b-3

RF door C4208b-1 C4208b-9

LR door C4208b-6 C4208b-7

RR door C4208b-5 C4208b-4

Instrument panel C4208b-15 C4208b-14
VME51 (BN/BU) RME51 (WH/BU)

D24 CHECK THE SPEAKER CIRCUITS FOR A SHORT TO
VOLTAGE
Yes
• Connect: Audio Amplifier C4208b . TEST the system for normal
• Disconnect: Audio Amplifier C4208a . operation.
• Ignition ON.
• Measure the voltage between the suspect speaker, harness side No
and ground as follows: GO to D25 .

Speaker Lead Lead
LF door C592a-1 Ground
VME07 (WH)
C592a-2 Ground
RME07 (WH/BN)
RF door C692a-1 Ground
VME10 (WH/VT)
C692a-2 Ground
RME10 (WH/OG)
LR door C702-1 Ground
VME09 (WH/GN)
C702-2 Ground
RME09 (BN/YE)
RR door C802-1 Ground
VME12 (BN/WH)
C802-2 Ground
RME12 (BN/BU)
Instrument panel C2363-1 Ground
VME06 (GN)
C2363-2 Ground
RME06 (GY/YE)

D25 CHECK THE SPEAKER CIRCUITS FOR AN OPEN OR
SHORT TO GROUND
Yes
• Ignition OFF. INSTALL a new audio amplifier.
• Measure the resistance between the audio amplifier, harness REFER to Audio Amplifier in
side and the suspect speaker, harness side; and between the this section. TEST the system for
audio amplifier, harness side and ground as follows: normal operation.
No
Suspect Positive Meter Negative TEST the system for normal
Speaker Lead Meter Lead Circuit operation.
LF door C4208a-7 C592a-1, then VME07 (WH)
ground
C4208a-6 C592a-2, then RME07
ground (WH/BN)
RF door C4208a-5 C692a-1, then VME10
ground (WH/VT)
C4208a-4 C692a-2, then RME10
ground (WH/OG)
LR door C4208a-9 C702-1, then VME09

ground (WH/GN)
C4208a-8 C702-2, then RME09
ground (BN/YE)
RR door C4208a-3 C802-1, then VME12
ground (BN/WH)
C4208a-2 C802-2, then RME12
ground (BN/BU)
Instrument C4208a-11 C2363-1, then VME06 (GN)
panel ground
C4208a-10 C2363-2, then RME06
ground (GY/YE)
• Are the resistances less than 5 ohms between the audio

amplifier and the suspect speaker, and greater than 10,000
ohms between the audio amplifier and ground?
D26 CHECK THE AUDIO CIRCUITS TO THE AUDIO
AMPLIFIER FOR A SHORT TO VOLTAGE
Yes
• Connect: ACM C240a (Except Instrument Panel Speaker TEST the system for normal
Concern) or C240d (Instrument Panel Speaker Concern) . operation.
• Ignition ON.
• Measure the voltage between the audio amplifier, harness side No
and ground as follows: GO to D27 .

Speaker Lead Lead
LF door C4208b-2 Ground
VME07 (WH)
C4208b-3 Ground
RME07 (WH/BN)
RF door C4208b-1 Ground
VME10 (WH/VT)
C4208b-9 Ground
RME10 (WH/OG)
LR door C4208b-6 Ground
VME09 (WH/GN)
C4208b-7 Ground
RME09 (BN/YE)
RR door C4208b-5 Ground
VME12 (BN/WH)
C4208b-4 Ground
RME12 (BN/BU)
Instrument panel C4208b-15 Ground
VME51 (BN/BU)
C4208b-14 Ground
RME51 (WH/BU)

D27 CHECK THE AUDIO CIRCUITS TO THE AUDIO
AMPLIFIER FOR AN OPEN OR SHORT TO GROUND
Yes
• Measure the resistance between the ACM , harness side and
the audio amplifier, harness side; and between the ACM , No
harness side and ground as follows: REPAIR the circuit in question.
operation.
Suspect Positive Negative Meter

Speaker Meter Lead Lead Circuit
LF door C240a-8 C4208b-2, then VME07
ground (WH)
C240a-21 C4208b-3, then RME07

ground (WH/BN)
RF door C240a-11 C4208b-1, then VME10
ground (WH/VT)
C240a-12 C4208b-9, then RME10
ground (WH/OG)
LR door C240a-9 C4208b-6, then VME09
ground (WH/GN)
C240a-22 C4208b-7, then RME09
ground (BN/YE)
RR door C240a-10 C4208b-5, then VME12
ground (BN/WH)
C240a-23 C4208b-4, then RME12
ground (BN/BU)
Instrument C240d-6 C4208b-15, then VME51
panel ground (BN/BU)
C2407-2 C4208b-14, then RME51
ground (WH/BU)
• Are the resistances less than 5 ohms between the audio

amplifier and the suspect speaker, and greater than 10,000
ohms between the audio amplifier and ground?
D28 CHECK FOR CORRECT ACM OPERATION
Yes
• Disconnect all the ACM connectors. INSTALL a new ACM . REFER
• Check for: to Audio Control Module (ACM)
♦ corrosion â Fusion or Audio Control
♦ damaged pins Module (ACM) â MKZ in this
♦ pushed-out pins section. TEST the system for
• Connect all the ACM connectors and make sure they seat normal operation.
correctly.
corroded connector. CLEAR any
DTCs present.
Pinpoint Test E: No Sound From One Or More Speakers (Not All Speakers) â SonyÂ® Sound
Normal Operation
The Audio Front Control Module (ACM) directs the audio signals to the audio Digital Signal Processing
(DSP) module in the form of an AC voltage. The audio DSP module boosts the audio signals and sends them
to the speakers. The audio DSP module provides internal circuit protection for shorts to ground or shorts to
voltage.
A short to ground or short to voltage in the circuit to one of the speakers may cause multiple speakers to lose
sound due to the built-in overload protection feature of the audio DSP module. In this case, a speaker fault
DTC sets, and this pinpoint test should be followed to isolate the damaged circuit.
The ACM sends the audio signals to the audio DSP module in the following banks:
Speaker Bank Speakers

LH front (without navigation) All LH speakers
LH front (navigation) LF door, LF tweeter, LH instrument panel
RH front (without navigation) All RH speakers
RH front (navigation) RF door, RF tweeter, RH instrument panel
LH rear (navigation) LR door
RH rear (navigation) RR door
Center imaging (navigation) Center instrument panel, LH parcel shelf, RH parcel shelf
Subwoofer (navigation) Subwoofer #1, subwoofer #2
For vehicles with navigation, it is also important to note that if the navigation voice guidance setting is set too
low, it may appear that the front speakers intermittently produce no sound. Make sure the voice guidance
setting is set high enough to hear the voice guidance commands before addressing a concern with the front
speakers.

01, 11, 12, 13 Set by the audio DSP module when a failure is detected in the center
• B1A01 front imaging speaker (part of the instrument panel speaker) circuit.
â

Speaker
#1
01, 11, 12, 13 Set by the audio DSP module when a failure is detected in the LH front
• B1A02 door speaker circuit.
â
Speaker
#2
01, 11, 12, 13 Set by the audio DSP module when a failure is detected in the LH
• B1A03 tweeter circuit.
â
Speaker
#3
01, 11, 12, 13 Set by the audio DSP module when a failure is detected in the LH rear
â
Speaker
#4
01, 11, 12, 13 Set by the audio DSP module when a failure is detected in the parcel
• B1A05 shelf speaker circuit.
â
Speaker
#5
01, 11, 12, 13 Set by the audio DSP module when a failure is detected in the RH front
â
Speaker
#6
11, 12, 13 Set by the audio DSP module when a failure is detected in the RH
• B1A07 tweeter circuit.
â
Speaker
#7
11, 12, 13 Set by the audio DSP module when a failure is detected in the RH rear
â
Speaker
#8
• B1A09 subwoofer circuit.
â
Speaker
#9
11, 12, 13 Set by the audio DSP module when a failure is detected in the LH
• B1A10 subwoofer circuit.
â
Speaker
#10
• Fuse

• Speaker
• Audio DSP module
• ACM
PINPOINT TEST E: NO SOUND FROM ONE OR MORE SPEAKERS (NOT ALL SPEAKERS) â SONYÂ® SOUND
Section 414-01 .

E1 CHECK FOR AN AUDIO SIGNAL TO THE
SUSPECT SPEAKER
Yes
• Ignition OFF. INSTALL a new speaker for the suspect
• Disconnect: Suspect Speaker. speaker. REFER to the appropriate
• Operate the audio system in radio tuner (AM/FM) removal and installation procedure in this
mode. section. TEST the system for normal
• Measure the AC voltage between the suspect speaker operation.
No
GO to E2 .

Suspect Speaker Lead Lead
LH front door C523-1 C523-2
VME07 (WH) RME07

(WH/BN)
RH front door C612-1 C612-2
VME10 RME10
(WH/VT) (WH/OG)
LH rear door C702-1 C702-2
VME09 RME09
(WH/GN) (BN/YE)
RH rear door C802-1 C802-2
VME12 RME12
(BN/WH) (BN/BU)
Instrument panel C2359-1 C2359-2
speaker
VME06 (GN) RME06
(GY/YE)
LH tweeter
PINPOINT TEST E: NO SOUND FROM ONE OR MORE SPEAKERS (NOT ALL SPEAKERS) â5755SONYÂ®
C591-1 C591-2
VME08 RME08
(GN/OG) (GY/OG)
VME11 RME11
(VT/OG) (YE/OG)
Rear center C3306-1 C3306-2
speaker
VME30 RME30
(GN/BN) (VT/BN)
LH Subwoofer C3120-1 C3120-2
VME01 RME01 (GY)

(GN/VT)
RH Subwoofer C3121-1 C3121-2
VME02 (VT) RME02 (YE)

E2 CHECK THE AUDIO DSP MODULE VOLTAGE
SUPPLY
Yes
• Disconnect: Audio DSP Module C4240a.
• Measure the voltage between the audio DSP module, No
harness side and ground as follows: VERIFY the Battery Junction Box (BJB)
fuse 19 (25A) is OK. If OK, REPAIR the
circuit in question. TEST the system for
normal operation. If not OK, REFER to
the Wiring Diagrams Manual to identify
Positive Meter Lead Negative Meter Lead the possible causes of the circuit short.
C4240a-5 Ground
SBP19 (BU/RD)
C4240a-6 Ground
SBP19 (BU/RD)

E3 CHECK THE AUDIO DSP MODULE GROUND
CIRCUITS FOR CONTINUITY

• Disconnect: Negative Battery Cable. GO to E4 .
• Measure the resistance between the audio amplifier,
REPAIR the circuit in question. TEST the
Positive Meter Lead Negative Meter Lead

C4240a-13 Ground
GD148 (BK/YE)
C4240a-14 Ground
GD148 (BK/YE)

E4 CHECK FOR AN AUDIO SIGNAL AT THE
AUDIO DSP MODULE
Yes
• Connect: Audio DSP Module C4240a.
• Disconnect: Audio DSP Module C4240c. No
• Operate the audio system in radio tuner (AM/FM) GO to E7 .
mode.
• Measure the AC voltage between the audio DSP
module pins, harness side as follows:
Positive Meter Negative

Suspect Speaker Lead Meter Lead
LH front door or C4240c-7 C4240c-17
LH tweeter
VME07 (WH) RME07
(WH/BN)
RH front door or C4240c-9 C4240c-19
RH tweeter
VME10 RME10
(WH/VT) (WH/OG)
LH rear door C4240c-8 C4240c-18
VME09 RME09
(WH/GN) (BN/YE)
RH rear door C4240c-10 C4240c-20
VME12 RME12
(BN/WH) (BN/BU)
Instrument panel or C4240c-6 C4240c-16
rear center
VME51 RME51
(BN/BU) (WH/BU)
Subwoofer C4240c-5 C4240c-15
VME22 RME22
(VT/GN) (GN/WH)

E5 CHECK THE SPEAKER CIRCUITS FOR A
SHORT TO VOLTAGE
Yes
• Ignition OFF. REPAIR the circuit in question. TEST the
• Connect: Audio DSP Module C4240c. system for normal operation.
• Disconnect: Audio DSP Module C4240b (Except
Subwoofer Concern). No
• Disconnect: Audio DSP Module C4240a (Subwoofer GO to E6 .
Concern).
• Ignition ON.
• Measure the voltage between the suspect speaker,
harness side and ground as follows:

Speaker Lead Lead
LH front door C591-1 Ground
VME08
(GN/OG)
C591-2 Ground
RME08
(GY/OG)
RH front door C612-1 Ground
VME10
(WH/VT)
C612-2 Ground
RME10
(WH/OG)
LH rear door C702-1 Ground
VME09
(WH/GN)
C702-2 Ground
RME09
(BN/YE)
RH rear door C802-1 Ground
VME12
(BN/WH)
C802-2 Ground
RME12
(BN/BU)
Instrument C2359-1 Ground
panel
VME06 (GN)
C2359-2 Ground
RME06
(GY/YE)
VME08
(GN/OG)
C591-2 Ground
RME08
(GY/OG)
VME11
(VT/OG)
C691-2 Ground
RME11
(YE/OG)
Rear center C3306-1 Ground
speaker
VME30
(GN/BN)
C3306-2 Ground
RME30
(VT/BN)
LH subwoofer C3120-1 Ground
VME01
(GN/VT)
C3120-2 Ground
RME01 (GY)
RH subwoofer C3121-1 Ground
VME02 (VT)
C3121-2 Ground
RME02 (YE)

E6 CHECK THE SPEAKER CIRCUITS FOR AN
Yes
• Measure the resistance between the audio DSP
module, harness side and the suspect speaker, harness No
side; and between the audio DSP module, harness REPAIR the circuit in question. TEST the
side and ground as follows: system for normal operation.
Negative
Suspect Positive Meter
LH front C4240b-2 C523-1, VME07
door then (WH)
ground
C4240b-10 C523-2, RME07
then (WH/BN)
ground
RH front C4240b-6 C612-1, VME10
door then (WH/VT)
ground
C4240b-14 C612-2, RME10
then (WH/OG)
ground
LH rear door C4240b-4 C702-1, VME09
then (WH/GN)
ground
C4240b-12 C702-2, RME09
then (BN/YE)
ground
RH rear door C4240b-8
C802-1, VME12
then (BN/WH)
ground
C4208b-16 C802-2, RME12
then (BN/BU)
ground
Instrument C4240b-1 C2359-1, VME06
panel then (GN)
ground
C4240b-9 C2359-2, RME06
then (GY/YE)
ground
LH tweeter C4240b-3 C591-1, VME08
then (GN/OG)
ground
C4240b-11 C591-2, RME08
then (GY/OG)
ground
RH tweeter C4240b-7 C691-1, VME11
then (VT/OG)
ground
C4240b-15 C691-2, RME11
then (YE/OG)
ground
Rear center C4240b-5 C3306-1, VME30
speaker then (GN/BN)
ground
C4208b-13 C3306-3, RME30
then (VT/BN)
ground
LH C4240a-1 C3120-1, VME01
Subwoofer then (GN/VT)
ground
C4240a-9 C3120-2, RME01
then (GY)
ground
RH C4240a-2 C3121-1, VME02
Subwoofer then (VT)
ground
C4240a-10 C3121-2, RME02
then (YE)
ground

audio DSP module and the suspect speaker, and
greater than 10,000 ohms between the audio DSP
module and ground?
E7 CHECK THE AUDIO CIRCUITS TO THE AUDIO
DSP MODULE FOR A SHORT TO VOLTAGE

• Disconnect: ACM C240a (Except Subwoofer REPAIR the circuit in question. CLEAR
Concern). any DTCs present. TEST the system for
• Disconnect: ACM C240d (Subwoofer Concern). normal operation.
• Disconnect: Audio DSP Module C4240c.
• Ignition ON. No
• Measure the voltage between the audio DSP module GO to E8 .
pins, harness side and ground as follows:
Positive Meter Negative

Suspect Speaker Lead Meter Lead
LH front door or C4240c-7 Ground
LH A-pillar
VME07 (WH)
C4240c-17 Ground
RME07
(WH/BN)
RH front door or C4240c-9 Ground
RH A-pillar
VME10
(WH/VT)
C4240c-19 Ground
RME10
(WH/OG)
LH rear door or LH C4240c-8 Ground
D-pillar
VME09
(WH/GN)
C4240c-18 Ground
RME09
(BN/YE)
RH rear door or RH C4240c-10 Ground
D-pillar
VME12
(BN/WH)
C4240c-20 Ground
RME12
(BN/BU)
Instrument panel or C4240c-6 Ground
rear center
VME51
(BN/BU)
C4240c-16 Ground
RME51
(WH/BU)
Subwoofer C4240c-5 Ground
VME22
(VT/GN)
C4240c-15 Ground
RME22
(GN/WH)

E8 CHECK THE AUDIO CIRCUITS TO THE AUDIO
DSP MODULE FOR AN OPEN OR SHORT TO
GROUND
Yes
• Measure the resistance between the audio DSP
module, harness side and the ACM , harness side; No
and between the audio DSP module, harness side and REPAIR the circuit in question. CLEAR
ground as follows: any DTCs present. TEST the system for
normal operation.
Negative
Suspect Positive Meter
LH front C4240c-7 C240a-8, VME07
door or LH then ground (WH)
tweeter
C4240c-17 C240a-21, RME07
then ground (WH/BN)
RH front C4240c-9 C240a-11, VME10
door or RH then ground (WH/VT)
tweeter
C4240c-19 C240a-12, RME10
then ground (WH/OG)
LH rear door C4240c-8 C240a-9, VME09
then ground (WH/GN)
C4240c-18 C240a-22, RME09
then ground (BN/YE)
RH rear door C4240c-10 C240a-10, VME12
then ground (BN/WH)
C4240c-20 C240a-23, RME12

then ground (BN/BU)
Instrument C4240c-6 C240d-5, VME51
panel or rear then ground (BN/BU)
center
C4240c-16 C240d-6, RME51
then ground (WH/BU)
Subwoofer C4240c-5 C240d-1, VME22
then ground (VT/GN)
C4240c-15 C240d-2, RME22
then ground (GN/WH)

audio DSP module and the ACM and greater than
10,000 ohms between the audio DSP module and
ground?
E9 CHECK FOR CORRECT ACM OPERATION
Yes
• Ignition OFF. INSTALL a new ACM . REFER to Audio
• Connect: All Disconnected Connectors. Control Module (ACM) â Fusion or
• Disconnect all the ACM connectors. Audio Control Module (ACM) â MKZ
• Check for: in this section. TEST the system for
♦ damaged pins
• Connect all the ACM connectors and make sure they The system is operating correctly at this
seat correctly. time. The concern may have been caused
• Operate the system and determine if the concern is by a loose or corroded connector. CLEAR
still present. any DTCs present.
E10 CHECK FOR CORRECT AUDIO DSP MODULE
OPERATION
Yes
• Ignition OFF. INSTALL a new audio DSP module.
• Connect: All Disconnected Connectors. REFER to Audio Digital Signal
• Disconnect all the audio DSP module connectors. Processing (DSP) Module in this section.

♦ corrosion
♦ damaged pins No
♦ pushed-out pins The system is operating correctly at this
• Connect all the audio DSP module connectors and time. The concern may have been caused
make sure they seat correctly. by a loose or corroded connector. CLEAR
• Operate the system and determine if the concern is any DTCs present.
still present.
Pinpoint Test F: No Sound From One Or More Speakers (Not All Speakers) â THXÂ® Sound
Normal Operation
The Audio Front Control Module (ACM) directs the audio signals to the audio Digital Signal Processing
(DSP) module in the form of an AC voltage. The audio DSP module boosts the audio signals and sends them
to the speakers. The audio DSP module provides internal circuit protection for shorts to ground or shorts to
voltage.
A short to ground or short to voltage in the circuit to one of the speakers may cause multiple speakers to lose
sound due to the built-in overload protection feature of the audio DSP module. In this case, a speaker fault
DTC sets, and this pinpoint test should be followed to isolate the damaged circuit.
The ACM sends the audio signals to the audio DSP module in the following banks:
Speaker Bank Speakers

LH front (without navigation) All LH speakers
LH front (navigation) LF door, LF tweeter, LH instrument panel
RH front (without navigation) All RH speakers
RH front (navigation) RF door, RF tweeter, RH instrument panel
LH rear (navigation) LR door
RH rear (navigation) RR door
Center imaging (navigation) Center instrument panel, LH parcel shelf, RH parcel shelf
Subwoofer (navigation) Subwoofer #1, subwoofer #2
For vehicles with navigation, it is also important to note that if the navigation voice guidance setting is set too
low, it may appear that the front speakers intermittently produce no sound. Make sure the voice guidance
setting is set high enough to hear the voice guidance commands before addressing a concern with the front
speakers.


01, 11, 12, 13 Set by the ACM when a fault is detected in the LF speaker output
• B1A01 â circuits, or by the audio DSP module when a failure is detected in
Speaker #1 the LH front imaging speaker (part of the instrument panel
speaker) circuit.
01, 11, 12, 13 Set by the ACM when a fault is detected in the RF speaker output
Speaker #2 the center front imaging speaker (part of the instrument panel
speaker) circuit.
01, 11, 12, 13 Set by the ACM when a fault is detected in the RR speaker output
Speaker #3 the RH front imaging speaker (part of the instrument panel
speaker) circuit.
01, 11, 12, 13 Set by the ACM when a fault is detected in the LR speaker output
Speaker #4 the LH front door tweeter circuit.
01, 11, 12, 13 Set by the ACM when a fault is detected in the subwoofer output
Speaker #5 the RH front door tweeter circuit.
01, 11, 12, 13 Set by the ACM when a fault is detected in the instrument panel
• B1A06 â speaker output circuits, or by the audio DSP module when a
Speaker #6 failure is detected in the parcel shelf speaker circuit.
• B1A07 â front door speaker circuit.
Speaker #7
• B1A08 â front door speaker circuit.
Speaker #8
• B1A09 â rear door speaker circuit.
Speaker #9
• B1A10 â subwoofer circuit.
Speaker #10
• B1A11 â subwoofer circuit.
Speaker #11
• B1A12 â rear door speaker circuit.
Speaker #12
• Fuse
• Speaker

• ACM
PINPOINT TEST F: NO SOUND FROM ONE OR MORE SPEAKERS (NOT ALL SPEAKERS) â THXÂ® SOUND
Section 414-01 .

F1 CHECK THE AUDIO SIGNALS TO THE SUSPECT
SPEAKER
Yes
• Disconnect: Suspect Speaker . suspect speaker. REFER to the
• Operate the audio system in radio tuner (AM/FM) mode. appropriate removal and install
• Measure the AC voltage between the suspect speaker pins, procedure in this section. CLEAR
harness side as follows: any DTCs present. TEST the
No
GO to F2 .
LH subwoofer C3307-1 C3307-2
VME01 (GN/VT) RME01 (GY)

LR door C702-1 C702-2

LF door C523-1 C523-2

VME08 (GN/OG) RME08 (GY/OG)

LH front imaging C2358-1 C2358-4
VME28 (BN/VT) RME28 (BN/GN)

Center front C2358-2 C2358-5
imaging
VME06 (GN) RME06 (GY/YE)
RH front imaging C2358-3 C2358-6
VME29 (GN/WH) RME29 (BU/WH)

PINPOINT TEST F: NO SOUND FROM ONE OR MORE SPEAKERS (NOT ALL SPEAKERS) â5767THXÂ®
RF door C612-1 C612-2

RR door C802-1 C802-2

RH subwoofer C3308-1 C3308-2
VME02 (VT) RME02 (YE)

Rear center C3306-1 C3306-2
imaging
VME30 (GN/BN) RME30 (VT/BN)

F2 CHECK THE AUDIO SIGNALS TO THE AUDIO DSP
MODULE
Yes
• Disconnect: Audio DSP Module C4235c .
• Operate the audio system in radio tuner (AM/FM) mode. No
• Measure the AC voltage between the audio DSP module GO to F7 .
Positive Negative
Suspect Speaker Meter Lead Meter Lead
All LH speakers (without C4235c-7 C4235c-17
navigation), LF door or LF
tweeter (with navigation) VME07 RME07
(WH) (WH/BN)
All RH speakers (without C4235c-8 C4235c-18
navigation), RF door or RF
tweeter (with navigation) VME10 RME10
(WH/VT) (WH/OG)
LR door (with navigation) C4235c-4 C4235c-14
VME09 RME09
(WH/GN) (BN/YE)
RR door (with navigation) C4235c-10 C4235c-20
VME12 RME12
(BN/WH) (BN/BU)
Instrument panel or parcel C4235c-9 C4235c-19
shelf (with navigation)
VME51 RME51
(BN/BU) (WH/BU)
Subwoofer #1 or #2 C4235c-5 C4235c-15
VME22 RME22
(VT/GN) (GN/WH)

F3 CHECK THE AUDIO DSP MODULE VOLTAGE
SUPPLY
Yes
• Disconnect: Audio DSP Module C4235a .
• Operate the audio system in radio tuner (AM/FM) mode. No
• Measure the voltage between the audio DSP module, VERIFY the Battery Junction Box
harness side and ground as follows: (BJB) fuse 20 (20A) or 21 (20A) is
OK. If OK, REPAIR the circuit.
operation. If not OK, REFER to the
Wiring Diagrams Manual to
Positive Meter Negative Meter identify the possible causes of the
Lead Lead Circuit circuit short.
C4235a-9 Ground SBB20
(GN/RD)
(GN/RD)
(GY/RD)
(GY/RD)

F4 CHECK THE AUDIO DSP MODULE GROUND
Yes
• Measure the voltage between the audio DSP module, No
harness side and ground as follows: REPAIR the circuit in question.
operation.

Lead Lead Circuit
C4235a-22 Ground GD148
(BK/YE)
(BK/YE)
(BK/YE)

F5 CHECK THE CIRCUITS TO THE SUSPECT SPEAKER
Yes
• Disconnect: Audio DSP Module C4235a and C4235b . CLEAR any DTCs present. TEST
• Measure the voltage between the suspect speaker, harness
side and ground as follows: No
GO to F6 .

Speaker Lead Lead
LH subwoofer Ground
C3307-1
VME01 (GN/VT)
C3307-2 Ground
RME01 (GY)
LR door C702-1 Ground
VME09 (WH/GN)
C702-2 Ground
RME09 (BN/YE)
LF door C523-1 Ground
VME07 (WH)
C523-1 Ground
RME07 (WH/BN)
VME08 (GN/OG)
C569-2 Ground
RME08 (GY/OG)
LH front C2358-1 Ground
imaging
VME28 (BN/VT)
C2358-4 Ground
RME28 (BN/GN)

Center front C2358-2 Ground
imaging
VME06 (GN)
C2358-5 Ground
RME06 (GY/YE)
RH front imaging C2358-3 Ground
VME29 (GN/WH)
C2358-6 Ground
RME29 (BU/WH)
VME11 (VT/OG)
C613-2 Ground
RME11 (YE/OG)
RF door C612-1 Ground
VME10 (WH/VT)
C612-2 Ground
RME10 (WH/OG)
RR door C802-1 Ground
VME12 (BN/WH)
C802-2 Ground
RME12 (BN/BU)
Rear center C3306-1 Ground
imaging
VME30 (GN/BN)
C3306-2 Ground
RME30 (VT/BN)
RH subwoofer C3308-1 Ground
VME02 (VT)
C3308-2 Ground
RME02 (YE)

F6 CHECK THE CIRCUITS TO THE SUSPECT SPEAKER

• Measure the resistance between the suspect speaker, GO to F9 .
harness side and the audio DSP module, harness side; and
between the suspect speaker, harness side and ground as No
follows: REPAIR the circuit in question.
CLEAR any DTCs present. TEST
Suspect Positive Negative

LH C3307-1 C4235a-16, VME01
subwoofer then ground (GN/VT)
C3307-2 C4235a-4, then RME01
ground (GY)
LR door C702-1 C4235a-18, VME09
then ground (WH/GN)
C702-2 C4235a-6, then RME09
ground (BN/YE)
LF door C523-1 C4235b-9, then VME07
ground (WH)
C523-2 C4235b-2, then RME07
ground (WH/BN)
LH tweeter C569-1 C4235b-11, VME08
then ground (GN/OG)
C569-2 C4235b-4, then RME08
ground (GY/OG)
LH front C2358-1 C4235a-14, VME28
imaging then ground (BN/VT)
C2358-4 C4235a-2, then RME28
ground (BN/GN)

Center front C2358-2 C4235b-13, VME06
imaging then ground (GN)
C2358-5 C4235b-6, then RME06
ground (GY/YE)
RH front C2358-3 C4235b-14, VME29
imaging then ground (GN/WH)
C2358-6 C4235b-7, then RME29
ground (BU/WH)
RH tweeter C613-1 C4235b-10, VME11
then ground (VT/OG)
C613-2 C4235b-3, then RME11
ground (YE/OG)
RF door C612-1 C4235b-8, then VME10
ground (WH/VT)
C612-2 C4235b-1, then RME10

ground (WH/OG)
RR door C802-1 C4235a-17, VME12
then ground (BN/WH)
C802-2 C4235a-5, then RME12
ground (BN/BU)
Rear center C3306-1 C4235b-12, VME30
imaging then ground (GN/BN)
C3306-2 C4235b-5, then RME30
ground (VT/BN)
RH C3308-1 C4235a-15, VME02
subwoofer then ground (VT)
C3308-2 C4235a-3, then RME02 (YE)
ground
• Are the resistances less than 5 ohms between the suspect

speaker and the audio DSP module, and greater than
10,000 ohms between the suspect speaker and ground?
F7 CHECK THE AUDIO CIRCUITS TO THE AUDIO DSP
MODULE FOR A SHORT TO VOLTAGE
Yes
• Disconnect: ACM C240a or C240d . CLEAR any DTCs present. TEST
• Measure the voltage between the audio DSP module,
GO to F8 .
Positive Negative
Suspect Speaker Meter Lead Meter Lead
All LH speakers (without C4235c-7 Ground
navigation), LF door or LF
tweeter (with navigation) VME07
(WH)
C4235c-17 Ground
RME07
(WH/BN)
All RH speakers (without C4235c-8 Ground
navigation), RF door or RF
tweeter (with navigation) VME10
(WH/VT)
C4235c-18 Ground
RME10
(WH/OG)
LR door (with navigation) C4235c-4 Ground
VME09
(WH/GN)
C4235c-14 Ground
RME09
(BN/YE)
RR door (with navigation) C4235c-10 Ground
VME12
(BN/WH)
C4235c-20 Ground
RME12
(BN/BU)
Instrument panel or parcel C4235c-9 Ground
shelf (with navigation)
VME51
(BN/BU)
C4235c-19 Ground
RME51
(WH/BU)
Subwoofer #1 or #2 C4235c-5 Ground
VME22
(VT/GN)
C4235c-15 Ground
RME22
(GN/WH)

F8 CHECK THE AUDIO CIRCUITS TO THE AUDIO DSP
MODULE FOR AN OPEN OR SHORT TO GROUND
Yes
• Measure the resistance between the ACM , harness side and
the audio DSP module, harness side; and between the ACM No
, harness side and ground as follows: REPAIR the circuit in question.
CLEAR any DTCs present. TEST
Without Navigation
Suspect Positive Negative Meter

All LH C240a-8 C4235c-7, then VME07
speakers ground (WH)
C240a-21 C4235c-17, RME07
then ground (WH/BN)
All RH C240a-11 C4235c-8, then VME10
speakers ground (WH/VT)
C240a-12 C4235c-18, RME10
then ground (WH/OG)
With Navigation

LF door, LF C240a-8 C4235c-7, VME07
tweeter then ground (WH)
C240a-21 C4235c-17, RME07
then ground (WH/BN)
RF door, RF C240a-11 C4235c-8, VME10
tweeter then ground (WH/VT)
C240a-12 C4235c-18, RME10
then ground (WH/OG)
LR door C240a-9 C4235c-4, VME09
then ground (WH/GN)
C240a-22 C4235c-14, RME09
then ground (BN/YE)
RR door C240a-10 C4235c-10, VME12

then ground (BN/WH)
C240a-23 C4235c-20, RME12
then ground (BN/BU)
Instrument C240d-5 C4235c-9, VME51
panel, parcel then ground (BN/BU)
shelf
C240d-6 C4235c-19, RME51
then ground (WH/BU)
Subwoofer #1, C240d-1 C4235c-5, VME22
subwoofer #2 then ground (VT/GN)
C240d-2 C4235c-15, RME22
then ground (GN/WH)
• Are the resistances less than 5 ohms between the ACM

and the audio DSP module, and greater than 10,000
ohms between the ACM and ground?
F9 CHECK FOR CORRECT AUDIO DSP MODULE
OPERATION
Yes
• Ignition OFF. INSTALL a new audio DSP
• Connect: All Disconnected Connectors . module. REFER to Audio Digital
• Disconnect all the audio DSP module connectors. Signal Processing (DSP) Module in
• Check for: this section. CLEAR any DTCs
♦ corrosion present. TEST the system for
♦ pushed-out pins
• Connect all the audio DSP module connectors and make No
sure they seat correctly. The system is operating correctly at
• Is the concern still present? connector. CLEAR any DTCs
present.
F10 CHECK FOR CORRECT ACM OPERATION
Yes
• Connect: All Disconnected Connectors . Audio Control Module (ACM) â

• Disconnect all the ACM connectors. MKZ in this section. CLEAR any
• Check for: DTCs present. TEST the system for
♦ damaged pins
• Connect all the ACM connectors and make sure they seat The system is operating correctly at
• Operate the system and determine if the concern is still been caused by a loose or corroded
present. connector. CLEAR any DTCs
• Is the concern still present? present.
Pinpoint Test G: No Sound From All Speakers
Normal Operation â All Vehicles
When the ignition is in the START position, voltage is supplied to the Audio Front Control Module (ACM)
through the START sense circuit. When the ACM receives this voltage, it mutes the speaker output.
Vehicles With SonyÂ® Sound or THXÂ® Sound
The ACM mutes the speaker output by removing the enable voltage to the audio Digital Signal Processing
(DSP) module when the ignition is in the START position to prevent popping in the speakers as a result of
voltage spikes during engine cranking. However, if there is a short to voltage on the enable circuit, the ACM
continuously mutes the audio output, resulting in no sound from all speakers.
To enable the audio DSP module, the ACM sends voltage through the enable circuit. The enable status is
based on the following voltage, as detected by the ACM :
• Less than 0.4 volt: amplifier disabled

• Between 3.8 and battery voltage: amplifier enabled
An open in the enable circuit causes the audio system to produce no sound because the enable signal does not
reach the audio DSP module.
• Fuse
• Audio DSP module (SonyÂ® sound, THXÂ® sound)
• ACM
PINPOINT TEST G: NO SOUND FROM ALL SPEAKERS
Section 414-01 .
Normal Operation â All Vehicles 5778


G1 CHECK THE START SENSE CIRCUIT FOR A SHORT
TO VOLTAGE
Yes
• Disconnect: ACM C240a . system for normal operation.
• Ignition ON.
• Measure the voltage between the ACM C240a-15, circuit No
CBP28 (GY/VT), harness side and ground. For SonyÂ® and THXÂ® sound
systems, GO to G2 .
For all other sound systems, GO to

G7 .

G2 CHECK THE AUDIO DSP MODULE VOLTAGE
SUPPLY
Yes
• Disconnect: Audio DSP Module C4240a (SonyÂ® Sound)
or C4235a (THXÂ® Sound) . No
• For SonyÂ® sound, measure the voltage between the audio VERIFY the Smart Junction Box
DSP module C4240a-5, circuit SBP19 (BU/RD), harness (SJB) fuse 19 (25A) (SonyÂ®), or
side and ground; and between the audio DSP module Battery Junction Box (BJB) fuses
C4240a-6, circuit SBP19 (BU/RD), harness side and 20 (20A) and 21 (20A) (THXÂ®)
ground. are OK. If OK, REPAIR the circuit
in question. TEST the system for
normal operation. If not OK,
REFER to the Wiring Diagrams
Manual to identify the possible
• For THXÂ® sound, measure the voltage between the audio

DSP module, harness side and ground as follows:

Lead Lead Circuit
(GN/RD)
(GN/RD)
PINPOINT TEST G: NO SOUND FROM ALL SPEAKERS 5779


(GY/RD)
(GY/RD)

G3 CHECK THE AUDIO DSP MODULE GROUND
Yes
• Disconnect: Negative Battery Cable . GO to G4 .
• For SonyÂ® sound, measure the resistance between the
audio DSP module C4240a-13, circuit GD148 (BK/YE), No
harness side and ground; and between the audio DSP REPAIR the circuit in question.
module C4240a-14, circuit GD148 (BK/YE), harness side TEST the system for normal
and ground. operation.
• For THXÂ® sound, measure the resistance between the

audio DSP module, harness side and ground as follows:

Lead Lead Circuit
C4235b-22 Ground GD148
(BK/YE)
(BK/YE)
(BK/YE)


G4 CHECK THE AUDIO DSP MODULE ENABLE
CIRCUIT FOR CORRECT VOLTAGE
Yes
• Connect: Negative Battery Cable . GO to G8 .
• Connect: Audio DSP Module C4240a (SonyÂ® Sound) or
C4235a (THXÂ® Sound) . No
• Disconnect: Audio DSP Module C4240c (SonyÂ® Sound) GO to G5 .
or C4235c (THXÂ® Sound) .
• Operate the audio system in radio tuner (AM/FM) mode.
• Measure the voltage between the audio DSP module
C4240c-3 (SonyÂ® sound) or C4235c-3 (THXÂ® sound),
circuit SME23 (VT/RD), harness side and ground.

Yes
• Disconnect: ACM C240d . system for normal operation.
• Ignition ON.
• Measure the voltage between the audio DSP module No
C4240c-3 (SonyÂ® sound) or C4235c-3 (THXÂ® sound), GO to G6 .
circuit SME23 (VT/RD), harness side and ground.

CIRCUIT FOR AN OPEN OR SHORT TO GROUND


• Measure the resistance between the audio DSP module GO to G7 .
C4240c-3 (SonyÂ® sound) or C4235c-3 (THXÂ® sound),
circuit SME23 (VT/RD), harness side and the ACM No
C240d-4, circuit SME23 (VT/RD), harness side; and REPAIR the circuit. TEST the
between the audio C4240c-3 (SonyÂ® sound) or C4235c-3 system for normal operation.
(THXÂ® sound), circuit SME23 (VT/RD), harness side
and ground.

DSP module and the ACM , and greater than 10,000
ohms between the audio DSP module and ground?
G7 CHECK FOR CORRECT ACM OPERATION
Yes
• Connect: All Disconnected Connectors . Audio Control Module (ACM) â
• Disconnect all the ACM connectors. Fusion or Audio Control Module
• Check for: (ACM) â MKZ in this section.
♦ corrosion TEST the system for normal
♦ pushed-out pins
• Connect all the ACM connectors and make sure they seat No
G8 CHECK FOR CORRECT AUDIO DSP MODULE
OPERATION
Yes
• Ignition OFF. INSTALL a new audio DSP
• Connect: All Disconnected Connectors . module. REFER to Audio Digital
• Disconnect all the audio DSP module connectors. Signal Processing (DSP) Module in
• Check for: this section. TEST the system for
♦ damaged pins
• Connect all the audio DSP module connectors and make The system is operating correctly at
sure they seat correctly. this time. The concern may have
• Operate the system and determine if the concern is still been caused by a loose or corroded
present. connector.
Pinpoint Test H: Poor Quality/Distorted/No Sound â SYNCÂ® System

Normal Operation
The Accessory Protocol Interface Module (APIM) sends left and right channel analog audio signals to the
Audio Front Control Module (ACM). This includes inputs from the Universal Serial Bus (USB) port, the
audio input jack, and a Bluetooth media device.

• APIM
• ACM
PINPOINT TEST H: POOR QUALITY/DISTORTED/NO SOUND â SYNCÂ® SYSTEM

H1 VERIFY THE OPERATION OF THE SYNCÂ®
SYSTEM AUDIO SOURCES
Yes
• Connect: Multi-Media Interface Tester . GO to H2 .
• Using the Multi-Media Interface Tester, test the audio
output for the audio input jack, USB port, and No
Bluetooth connection. If the concern is only with some (but not
• Is there poor quality/distorted/no sound from each all) of the audio sources, GO to
SYNCÂ® audio source? Symptom Chart - SYNCÂ® System to
diagnose the observed symptom.
If all audio sources operate correctly, the

concern is with the customer device.
H2 CHECK THE CIRCUITS FROM THE APIM FOR A
SHORT TO VOLTAGE
Yes
• Ignition OFF. REPAIR the circuit in question. TEST
• Disconnect: ACM C240c . the system for normal operation.
• Disconnect: APIM C3338 .
• Measure the voltage between the APIM , harness side No
and ground as follows: GO to H3 .
C3338-23 VME53 (VT/GN)
C3338-24 RME53 (BN/WH)
C3338-25 VME52 (BU)

C3338-26 RME52 (GY/OG)

H3 CHECK THE CIRCUITS FROM THE APIM FOR
AN OPEN OR SHORT TO GROUND
Yes
• Measure the resistance between the ACM , harness the system for normal operation.
side, and the APIM , harness side; and between the
ACM , harness side and ground as follows: No
GO to H4 .

Lead Lead Circuit
C240c-9 C3338-23, then VME53
ground (VT/GN)
C240c-10 C3338-24, then RME53
ground (BN/WH)
C240c-1 C3338-25, then VME52 (BU)
ground
C240c-2 C3338-26, then RME52
ground (GY/OG)

and the APIM , and greater than 10,000 ohms
between the ACM and ground?
PINPOINT TEST H: POOR QUALITY/DISTORTED/NO SOUND â SYNCÂ® SYSTEM 5784

H4 CHECK FOR CORRECT APIM OPERATION

Yes
• Connect: All Disconnected Connectors . INSTALL a new APIM . REFER to
• Disconnect the APIM connector. Accessory Protocol Interface Module
• Check for: (APIM) in this section. TEST the system
♦ corrosion for normal operation. If the concern is
♦ damaged pins still present, GO to H5 .
♦ pushed-out pins
• Connect the APIM connector and make sure it seats No
• Wait 2 minutes for the APIM to re-initalize. time. The concern may have been caused
present.
H5 CHECK FOR CORRECT ACM OPERATION
Yes
♦ corrosion Fusion or Audio Control Module (ACM)
♦ damaged pins â MKZ in this section. TEST the
♦ pushed-out pins system for normal operation.
seat correctly. No
• Operate the system and verify the concern is still The system is operating correctly at this
present. time. The concern may have been caused
• Is the concern still present? by a loose or corroded connector.
Pinpoint Test I: The Satellite Radio Is Inoperative/Does Not Operate Correctly
Normal Operation
Digital signals are received by the satellite radio antenna and sent to the Audio Front Control Module (ACM)
through the satellite radio antenna cable. The satellite radio receiver is internal to the ACM .
When a satellite radio subscription is activated, the Electronic Serial Number (ESN) of the built-in satellite
radio receiver is associated with the Vehicle Identification Number (VIN). As a result, the ACM cannot be
swapped from one vehicle to another.
When there is an open in the satellite radio antenna circuit, there is no satellite audio. The audio system
display indicates a satellite radio antenna concern when the audio system is operated in satellite radio mode.
To diagnose an open in the satellite radio antenna circuit, GO to Pinpoint Test B .
• DTC U2014:96 (Control Module Hardware: Component Internal Failure) â set by the
non-navigation (MKZ) or navigation (all) ACM when a fault is detected in the internal satellite radio
receiver. This results in complete loss of satellite radio functionality.
• Subscription status
• Satellite radio system concern

• ACM
PINPOINT TEST I: THE SATELLITE RADIO IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

I1 CHECK THE SATELLITE RADIO
DISPLAY
Yes
• Turn the audio system on. GO to I2 .
• Operate the audio system in satellite
radio mode and observe the Front No
Display Interface Module (FDIM) For vehicles without navigation, GO to Pinpoint Test K .
display.
• Does satellite radio information For vehicles with navigation, GO to Pinpoint Test L .
show on the FDIM display?
I2 VERIFY AN ACTIVE
SUBSCRIPTION
Yes
• Operate the audio system in satellite The subscription has expired. INFORM the customer to
radio mode and observe the FDIM contact Sirius to re-activate the subscription.
display.
• Does the display indicate the No
subscription has expired? GO to I3 .
I3 CHECK THE SATELLITE SIGNAL
PID (SAT_SIG_STR)
Yes
• Enter the following diagnostic mode GO to Pinpoint Test B .
on the scan tool: ACM DataLogger .
• Monitor the ACM PID No
(SAT_SIG_STR). For vehicles with navigation, GO to I4 .
• Does the PID indicate "No
Signal"? For all others, GO to I5 .
I4 CHECK THE ACM DTCs
Yes
• Retrieve the ACM DTCs. INSTALL a new ACM . REFER to Audio Control Module
• Is DTC U2014:96 present? (ACM) â Fusion or Audio Control Module (ACM) â
MKZ in this section. TEST the system for normal
operation.
No
GO to I5 .
I5 CHECK FOR CORRECT ACM
OPERATION
Yes
• Ignition OFF. INSTALL a new ACM . REFER to Audio Control Module
• Disconnect all the ACM connectors. (ACM) â Fusion or Audio Control Module (ACM) â
• Check for: MKZ in this section. TEST the system for normal
♦ corrosion operation.
♦ damaged pins
PINPOINT TEST I: THE SATELLITE RADIO IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

5786
• Connect all the ACM connectors and The system is operating correctly at this time. The concern
make sure they seat correctly. may have been caused by a loose or corroded connector.
• Operate the system and determine if
Pinpoint Test J: The Audio System Does Not Operate Correctly From The Front Controls Interface
Module (FCIM)
Normal Operation
When a button is pressed on the Front Controls Interface Module (FCIM), a signal is broadcast over the
Medium Speed Controller Area Network (MS-CAN) to the modules in the audio system. The FCIM is also
the customer interface with the HVAC module.
If the FCIM can no longer communicate on the MS-CAN (due to loss of power, ground, etc.), the audio
system remains in the operating state it was in prior to the failure. The steering wheel controls continue to
operate.
• DTC B2924 (Audio Button Stuck) â set by the non-navigation (Fusion) FCIM if a switch is
detected as active for greater than 3 seconds during the self-test, or for greater than 2 minutes during
normal operation. When this occurs, the FCIM disables the switch until it detects it as no longer
active.
• DTC U2013:63 (Switch Pack: Circuit / Component Protection Time-Out) â set by the
non-navigation (MKZ) or navigation (all) FCIM if a switch is detected as active for greater than 3
seconds during the self-test, or for greater than 2 minutes during normal operation. When this occurs,
the FCIM disables the switch until it detects it as no longer active.
• Communication network concern

• FCIM
PINPOINT TEST J: THE AUDIO SYSTEM DOES NOT OPERATE CORRECTLY FROM THE FCIM

J1 RETRIEVE ALL
CONTINUOUS DTCs
Yes
• Using the scan tool, retrieve REFER to DTC Charts in this section.
all continuous DTCs.
• Are DTCs U0184, No
U0184:00, U0255, or GO to J2 .
U0255:00 present in any
audio system module?
J2 CHECK FOR DTC B2924 OR
DTC U2013:63
Yes
• Clear the FCIM DTCs. INSTALL a new FCIM . REFER to Front Controls Interface
• Repeat the FCIM self-test, Module (FCIM) â Fusion or Front Controls Interface Module

making sure no FCIM (FCIM) â MKZ in this section. TEST the system for normal
buttons are pressed during operation.
the test.
• Is DTC B2924 or DTC No
U2013:63 present? GO to J3 .
J3 CHECK FOR CORRECT
FCIM OPERATION
Yes
• Disconnect the FCIM INSTALL a new FCIM . REFER to Front Controls Interface
connector. Module (FCIM) â Fusion or Front Controls Interface Module
• Check for: (FCIM) â MKZ in this section. CLEAR any DTCs present.
♦ corrosion TEST the system for normal operation.
♦ damaged pins
• Connect the FCIM The system is operating correctly at this time. The concern may
connector and make sure it have been caused by a loose or corroded connector. CLEAR any
seats correctly. DTCs present.
determine if the concern is
still present.
• Is the concern still
present?
Pinpoint Test K: An Individual Front Display Interface Module (FDIM) Display Is Inoperative â
Vehicles Without Navigation
Normal Operation
The Front Display Interface Module (FDIM) receives inputs via the Medium Speed Controller Area Network
(MS-CAN) from the following modules:
♦ Audio Front Control Module (ACM): audio system information

♦ Instrument Panel Cluster (IPC): compass heading information
♦ Accessory Protocol Interface Module (APIM): SYNCÂ® system information
♦ HVAC module: climate control system information
If the FDIM loses the signal from any of these modules, only that specific display is inoperative.
For the compass display, this pinpoint test is intended to diagnose a concern of the compass display being
blank. For any other concerns with the compass display, including the compass being inaccurate, refer to
Section 413-01 .

• FDIM
PINPOINT TEST K: AN INDIVIDUAL FDIM DISPLAY IS INOPERATIVE â VEHICLES WITHOUT NAVIGATION

K1 OBSERVE THE FDIM DISPLAY
PINPOINT TEST J: THE AUDIO SYSTEM DOES NOT OPERATE CORRECTLY FROM THE FCIM
5788
• Turn the audio system on and observe the FDIM Yes

screen. GO to Pinpoint Test N .
• Is the FDIM display completely inoperative?
No
GO to K2 .
K2 CHECK FOR LOST COMMUNICATION DTCs
SET IN THE FDIM
Yes
• Using the scan tool, retrieve all continuous DTCs. REFER to DTC Charts in this section.
• Is DTC U0155, U0155:00, U0184, U0184:00, U0197,
or U0197:00 present in the FDIM ? No
GO to K3 .
K3 CHECK THE FDIM DISPLAY SEGMENTS
Yes
• Carry out the Audio Display Test. Refer to Audio GO to K4 .
Control Module (ACM) Self-Diagnostic Mode in this
section. No
• Do all of the FDIM segments illuminate? GO to K5 .
K4 OBSERVE THE SPECIFIC INOPERATIVE
DISPLAY
Yes
• Observe the inoperative FDIM display while carrying The system is operating correctly at this
out the indicated diagnostic method as follows: time. INFORM the customer on the
operation of the FDIM display.
No
If the compass heading is inaccurate or
Inoperative indicates a calibration error, REFER to
Display Diagnostic Method Expected Results Section 413-01 to diagnose the compass.
Compass Drive the vehicle in The compass
an open area while display For all other concerns, GO to K5 .
observing the illuminates,
display. indicating a
directional
heading or a
calibration error.
Audio system Turn the audio The FDIM
system on, press the display updates to
AM/FM button, and show the change
adjust the volume. in audio setting.
SYNCÂ® Turn the audio The FDIM
system (if system on, press the display shows
equipped) phone button, and information
observe the display. relating to the
phone.
Climate Turn the climate The FDIM
control control system on, display updates to
system adjust the fan to show the change
high speed, and set in climate control
the temperature to setting.
various settings.
PINPOINT TEST K: AN INDIVIDUAL FDIM DISPLAY IS INOPERATIVE â VEHICLES WITHOUT

5789NAVIGA
• Does the inoperative display confirm the expected

results?
K5 CHECK FOR CORRECT FDIM OPERATION
Yes
• Ignition OFF. INSTALL a new FDIM . REFER to
• Disconnect the FDIM connector. Front Display Interface Module (FDIM)
• Check for: â Fusion or Front Display Interface
♦ corrosion Module (FDIM) â MKZ in this
♦ damaged pins section. TEST the system for normal
♦ pushed-out pins operation.
• Connect the FDIM connector and make sure it seats
correctly. No
• Operate the system and determine if the concern is The system is operating correctly at this
still present. time. The concern may have been caused
• Is the concern still present? by a loose or corroded connector.
Pinpoint Test L: An Individual FDIM Display Is Inoperative â Vehicles With Navigation
Normal Operation
The Front Display Interface Module (FDIM) display provides information based on the video signal from the
Audio Front Control Module (ACM). In addition to the information that the ACM controls for the navigation
and audio system, the ACM receives inputs via the Medium Speed Controller Area Network (MS-CAN) from
the following modules:
♦ Accessory Protocol Interface Module (APIM): SYNCÂ® system information (if equipped)
♦ HVAC module: climate control system information
If the ACM loses the signal from any of these modules, only that specific display becomes inoperative.

• FDIM
• ACM
PINPOINT TEST L: AN INDIVIDUAL FDIM DISPLAY IS INOPERATIVE â VEHICLES WITH NAVIGATION

L1 OBSERVE THE FDIM DISPLAY
Yes
• Turn the audio system on and observe the FDIM GO to Pinpoint Test O .
screen.
• Is the FDIM display completely inoperative? No
GO to L2 .
L2 CHECK THE FDIM DISPLAY SEGMENTS
Yes
• Carry out the Audio Display Test. Refer to Audio GO to L3 .
Control Module (ACM) Self-Diagnostic Mode in
this section. No

• Do all of the FDIM segments illuminate? GO to L6 .

L3 OBSERVE THE SPECIFIC INOPERATIVE
DISPLAY
Yes
• Observe the inoperative FDIM display while The system is operating correctly at this
carrying out the indicated diagnostic method as time. INFORM the customer on the
follows: operation of the FDIM displays.
No
GO to L4 .
Inoperative Diagnostic Expected

Display Method Results
Audio Turn the audio The FDIM
system system on, press display updates
the AM/FM to show the
button, and adjust change in audio
the volume. setting.
SYNCÂ® Turn the audio The FDIM
system (if system on, press display shows
equipped) the phone button, information
and observe the relating to the
display. phone.
Climate Turn the climate The FDIM
control control system on, display updates
system adjust the fan to to show the
high speed, and set change in
the temperature to climate control
various settings. setting.
• Does the inoperative display confirm the

expected results?
L4 CHECK FOR LOST COMMUNICATION DTCs
Yes
• Ignition ON. For DTC U0164, GO to Pinpoint Test AH .
• Clear continuous DTCs from all modules.
• Ignition OFF. For DTC U0197, GO to Pinpoint Test AK .
• Ignition ON.
• Wait at least 10 seconds. No
• Retrieve all continuous DTCs (from all modules). GO to L5 .
• Is DTC U0164, U0164:00, U0184, U0184:00,
U0197, or U0197:00 (if equipped with the
SYNCÂ® system) present in any module?
L5 CHECK FOR CORRECT FDIM OPERATION
Yes
• Ignition OFF. INSTALL a new FDIM . REFER to Front
• Disconnect the FDIM connector. Display Interface Module (FDIM) â
• Check for: Fusion or Front Display Interface Module
♦ corrosion (FDIM) â MKZ in this section. TEST the
♦ damaged pins system for normal operation. If the concern
♦ pushed-out pins is still present, GO to L6 .
PINPOINT TEST L: AN INDIVIDUAL FDIM DISPLAY IS INOPERATIVE â VEHICLES WITH NAVIGATION

5791
• Connect the FDIM connector and make sure it seats No

• Operate the system and determine if the concern is time. The concern may have been caused by
still present. a loose or corroded connector.
L6 CHECK FOR CORRECT ACM OPERATION
Yes
• Ignition OFF. INSTALL a new ACM . REFER to Audio
• Disconnect all the ACM connectors. Control Module (ACM) â Fusion or
• Check for: Audio Control Module (ACM) â MKZ in
♦ corrosion this section. TEST the system for normal
♦ pushed-out pins
• Connect all the ACM connectors and make sure No
they seat correctly. The system is operating correctly at this
• Operate the system and determine if the concern is time. The concern may have been caused by
still present. a loose or corroded connector.
Pinpoint Test M: The Audio System Does Not Operate Correctly From The Front Display Interface
Module (FDIM) â Vehicles With Navigation
Normal Operation
The Front Display Interface Module (FDIM) touchscreen sends a voltage signal to the Audio Front Control
Module (ACM) when a touch sector is pressed. The ACM then takes the appropriate action, which can be a
change in the audio system setting or broadcasting the information to the appropriate module through the
Medium Speed Controller Area Network (MS-CAN).
• DTC U0162:00 (Lost Communication With Navigation Display Module: No Sub Type Information)
â set by the ACM if it does not detect the FDIM for greater than 5 seconds with the ignition in the
RUN position. When this occurs, the touchscreen controls are inoperative and the FDIM may not
display correct (if any) information.

• FDIM
• ACM
PINPOINT TEST M: THE AUDIO SYSTEM DOES NOT OPERATE CORRECTLY FROM THE FDIM â VEHICLES
WITH NAVIGATION

M1 OBSERVE THE FDIM DISPLAY

• Turn the audio system on and observe the FDIM screen. Yes
• Is the FDIM display completely inoperative? GO to Pinpoint Test O .
No
GO to M2 .
M2 CHECK FOR AUDIO SYSTEM OPERATION FROM
THE FCIM
Yes
• Carry out various audio system functions using the GO to M3 .
Front Controls Interface Module (FCIM).
• Does the audio system operate correctly from the No
FCIM ? GO to Pinpoint Test J .
M3 CHECK THE TOUCHSCREEN TRANSMIT AND
RECEIVE CIRCUITS FOR A SHORT TO VOLTAGE
Yes
• Disconnect: FDIM C2410 . CLEAR any DTCs present. TEST the
• Disconnect: ACM C240b . system for normal operation.
• Ignition ON.
• Measure the voltage between the FDIM C2410-4, circuit No
CMN26 (BU/OG), harness side and ground; and GO to M4 .
between the FDIM C2410-10, circuit CMN24 (GY/VT),

M4 CHECK THE TOUCHSCREEN TRANSMIT AND
RECEIVE CIRCUITS FOR AN OPEN OR SHORT TO
GROUND
Yes
• Measure the resistance between the FDIM C2410-4,
circuit CMN26 (BU/OG), harness side and the ACM No
C240b-10, circuit CMN26 (BU/OG), harness side; and REPAIR the circuit in question.
between the FDIM C2410-4, circuit CMN26 (BU/OG), CLEAR any DTCs present. TEST the
harness side and ground. system for normal operation.
PINPOINT TEST M: THE AUDIO SYSTEM DOES NOT OPERATE CORRECTLY FROM THE FDIM
5793 â VE

circuit CMN24 (GY/VT), harness side and the ACM
C240b-5, circuit CMN24 (GY/VT), harness side; and
between the FDIM C2410-10, circuit CMN24 (GY/VT),
• Is the resistance less than 5 ohms between the FDIM

and the ACM , and greater than 10,000 ohms
between the FDIM and ground?
M5 ISOLATE THE FDIM
Yes
• Connect: ACM C240b . The cause of the concern was an
• Install a new FDIM . Refer to Front Display Interface inoperative FDIM . The system is now
Module (FDIM) â Fusion or Front Display Interface operating correctly.
Module (FDIM) â MKZ in this section.
• Ignition ON. No
• Attempt various commands from the FDIM GO to M6 .
touchscreen.
• Does the system operate correctly?
M6 CHECK FOR CORRECT ACM OPERATION
Yes
♦ pushed-out pins
seat correctly. The system is operating correctly at
• Operate the system and determine if the concern is still this time. The concern may have been
Pinpoint Test N: The Front Display Interface Module (FDIM) Is Completely Inoperative â Vehicles
Without Navigation
Normal Operation
The Front Display Interface Module (FDIM) receives power at all times. The ignition switch position message
is broadcast to the FDIM by the Smart Junction Box (SJB) via the Medium Speed Controller Area Network
(MS-CAN).

Information from the audio system, the climate control system, the SYNCÂ® system, and the compass
heading are shown on the FDIM display screen. If only one of these displays has a concern, GO to Pinpoint
Test K .

• FDIM
PINPOINT TEST N: THE FDIM IS COMPLETELY INOPERATIVE â VEHICLES WITHOUT NAVIGATION

N1 CHECK FOR SCAN TOOL
COMMUNICATION WITH THE FDIM
Yes
• Ignition ON. GO to N2 .
• Carry out the network test using the
scan tool. No
• Does the scan tool communicate REFER to Section 418-00 .
with the FDIM ?
N2 CHECK FOR CORRECT FDIM
OPERATION
Yes
• Ignition OFF. INSTALL a new FDIM . REFER to Front Display
• Disconnect the FDIM connector. Interface Module (FDIM) â Fusion or Front Display
• Check for: Interface Module (FDIM) â MKZ in this section. TEST
♦ corrosion the system for normal operation.
♦ damaged pins
• Connect the FDIM connector and The system is operating correctly at this time. The concern
make sure it seats correctly. may have been caused by a loose or corroded connector.
• Operate the system and determine if
Pinpoint Test O: The Front Display Interface Module (FDIM) Is Completely Inoperative â Vehicles
With Navigation
Normal Operation
The Audio Front Control Module (ACM) enables the Front Display Interface Module (FDIM) by sending
voltage through the enable circuit.
Video display information is sent to the FDIM from the ACM through a dedicated video cable. The video
cable is only serviced by overlaying a new component.
If there is a fault in the video cable, the FDIM may illuminate very dimly and have a greyish appearance. This
is because the enable circuit is still active and enables the illumination, but no video signal reaches the FDIM .
PINPOINT TEST N: THE FDIM IS COMPLETELY INOPERATIVE â VEHICLES WITHOUT NAVIGATION

5795
If the vehicle is equipped with a rear view camera, the video feed from the camera is hardwired to the FDIM .
For all other display information, including the climate control and SYNCÂ® system displays, messages are
sent to the ACM via the Medium Speed Controller Area Network (MS-CAN). The ACM then alters the video
feed to the FDIM based on the messages it receives.
• Fuse
• FDIM
• ACM
PINPOINT TEST O: THE FDIM IS COMPLETELY INOPERATIVE â VEHICLES WITH NAVIGATION
Section 414-01 .

O1 CHECK THE FDIM VOLTAGE SUPPLY
Yes
• Ignition OFF. GO to O2 .
• Disconnect: FDIM C2410 .
SBP14 (BN/RD), harness side and ground. VERIFY the Smart Junction Box
(SJB) fuse 14 (10A) is OK. If OK,
REPAIR the circuit. TEST the
system for normal operation. If not
Manual to identify the possible

O2 CHECK THE FDIM GROUND CIRCUIT FOR
CONTINUITY
Yes
• Disconnect: Negative Battery Cable . GO to O3 .
circuit GD116 (BK/VT), harness side and ground. No
REPAIR the circuit. TEST the


O3 CHECK THE FDIM ENABLE CIRCUIT FOR
CORRECT VOLTAGE
Yes
• Connect: Negative Battery Cable . GO to O6 .
• Ignition ON.
• Turn the audio system on using the power button on the No
Front Controls Interface Module (FCIM). GO to O4 .
• Measure the voltage between the FDIM C2410-5, circuit
CMN23 (WH/BU), harness side and ground.

O4 CHECK THE FDIM ENABLE CIRCUIT FOR A
SHORT TO VOLTAGE
Yes
• Disconnect: ACM C240b . system for normal operation.
• Ignition ON.
CMN23 (WH/BU), harness side and ground. GO to O5 .

O5 CHECK THE FDIM ENABLE CIRCUIT FOR AN

5797

• Measure the resistance between the FDIM C2410-5, GO to O6 .
circuit CMN23 (WH/BU), harness side and the ACM
C240b-4, circuit CMN23 (WH/BU), harness side; and No
between the FDIM C2410-5, circuit CMN23 (WH/BU), REPAIR the circuit. TEST the
harness side and ground. system for normal operation.
• Is the resistance less than 5 ohms between the FDIM

and the ACM , and greater than 10,000 ohms between
the FDIM and ground?
O6 ISOLATE THE VIDEO CABLE
Yes
• Connect: FDIM C2410 . inoperative video cable. The system
• Install a new video cable. Refer to Video Cable in this is now operating correctly.
section.
• Ignition ON. No
• Operate the audio system and observe the FDIM screen. GO to O7 .
O7 ISOLATE THE FDIM
Yes
• Install a new FDIM . Refer to Front Display Interface The cause of the concern was an
Module (FDIM) â Fusion or Front Display Interface inoperative FDIM . The system is
Module (FDIM) â MKZ in this section. now operating correctly.
• Ignition ON.
• Operate the audio system and observe the FDIM screen. No
• Does the system operate correctly? GO to O8 .
O8 CHECK FOR CORRECT ACM OPERATION
Yes
♦ damaged pins TEST the system for normal
• Connect all the ACM connectors and make sure they seat
correctly. No
• Operate the system and determine if the concern is still The system is operating correctly at
present. this time. The concern may have
connector.

5798
Pinpoint Test P: The Front Display Interface Module (FDIM) Does Not Display DVD Video Played
From The Audio Front Control Module (ACM) â Vehicles With Navigation
Normal Operation
Video from a DVD played in the Audio Front Control Module (ACM) is transmitted to the Front Display
Interface Module (FDIM) through dedicated video circuits. This video feed is separate from all other video
sources, so it is possible for the FDIM to operate correctly until a DVD video is played.
DVD video playback through the ACM is only enabled when the vehicle is in PARK. In all other gears, only
the DVD audio is played. This is normal operation.

• FDIM
• ACM
PINPOINT TEST P: THE FDIM DOES NOT DISPLAY DVD VIDEO PLAYED FROM THE ACM â VEHICLES WITH
NAVIGATION

P1 CHECK THE FDIM VIDEO FEED CIRCUITS FOR A
SHORT TO VOLTAGE
Yes
• Disconnect: ACM C240b . TEST the system for normal
• Disconnect: FDIM C2410 . operation.
• Ignition ON.
VMN20 (BN/VT), harness side and ground; and between the GO to P2 .
FDIM C2410-12, circuit RMN20 (WH/GN), harness side and
ground.

P2 CHECK THE FDIM VIDEO FEED CIRCUITS FOR AN


• Measure the resistance between the FDIM C2410-6, circuit REPAIR the circuit in question.
VMN20 (BN/VT), harness side and the ACM C240b-3, circuit TEST the system for normal
VMN20 (BN/VT), harness side; and between the FDIM operation.
C2410-6, circuit VMN20 (BN/VT), harness side and ground.
No
GO to P3 .
• Measure the resistance between the FDIM C2410-12, circuit

RMN20 (WH/GN), harness side and the ACM C240b-8,
circuit RMN20 (WH/GN), harness side; and between the
FDIM C2410-12, circuit RMN20 (WH/GN), harness side and
ground.
• Is the resistance less than 5 ohms between the FDIM and

the ACM , and greater than 10,000 ohms between the
FDIM and ground?
P3 ISOLATE THE FDIM
Yes
• Install a new FDIM . Refer to Front Display Interface Module inoperative FDIM . The system
(FDIM) â Fusion or Front Display Interface Module is now operating correctly.
(FDIM) â MKZ in this section.
• Ignition ON. No
• Operate the audio system and observe the FDIM screen. GO to P4 .
P4 CHECK FOR CORRECT ACM OPERATION
Yes
• Ignition OFF. INSTALL a new ACM . REFER
• Disconnect all the ACM connectors. to Audio Control Module (ACM)
• Check for: â Fusion or Audio Control
♦ corrosion Module (ACM) â MKZ in this
♦ damaged pins section. TEST the system for
♦ pushed-out pins normal operation.
• Connect all the ACM connectors and make sure they seat
correctly. No
• Operate the system and determine if the concern is still The system is operating correctly
present. at this time. The concern may
PINPOINT TEST P: THE FDIM DOES NOT DISPLAY DVD VIDEO PLAYED FROM THE ACM 5800
â VEHICL
• Is the concern still present? have been caused by a loose or

corroded connector.
Pinpoint Test Q: The Steering Wheel Controls Are Inoperative/Do Not Operate Correctly
Refer to Wiring Diagrams Cell 130 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Audio/Navigation for
Normal Operation
There are 3different steering wheel controls configurations:
• Without the SYNCÂ® system

♦ VOL-, VOL+, SEEK-, SEEK+, MEDIA
♦ All switches are wired to the Audio Front Control Module (ACM)
• SYNCÂ® system without navigation
♦ VOL-, VOL+, SEEK-, SEEK+, MEDIA, PHONE, OK
♦ The VOL-, VOL+, SEEK-, and SEEK+ switches are wired to the ACM . The remaining
switches are wired to the Accessory Protocol Interface Module (APIM).
• SYNCÂ® system with navigation
♦ VOL-, VOL+, SEEK-, SEEK+, VOICE, MEDIA, PHONE
♦ All switches are wired to the ACM
Voltage is sent from the ACM (or APIM ) to the steering wheel controls, and the same module grounds the
return circuit. The VOL-, VOL+, SEEK- and SEEK+ switches share signal and return circuits, while the
VOICE, MEDIA, PHONE and OK switches share separate signal and return circuits.
For all configurations, when a switch is pressed, the voltage is routed through a specific resistor value for each
function. The ACM (or APIM ) then uses the reference voltage to determine which control input function has
been selected.

Set by the non-navigation ACM when a steering wheel controls switch is detected
• B1117 â Audio as active for more than 120 seconds during normal operation, or for any duration
Steering Wheel during the self-test. A short to ground in the signal return circuit does not set this
Button Stuck DTC, as the reference voltage falls out-of-range, resulting in DTC B2404 being
(ACM) set.
Set by the ACM when the reference voltage to the steering wheel controls is
• B11BA:1C â out-of-range. This can be caused by a number of different failures on the steering
Steering Wheel wheel controls circuit except for a stuck switch or a short to ground in the signal
Audio Switch return circuit. This DTC applies to the VOL-, VOL+, SEEK-, SEEK+, and
Pack: Circuit MEDIA switches.
Voltage Out of
Range
Set by the ACM when a steering wheel control switch is detected as active for
• B11BA:63 â more than 120 seconds during normal operation, or for more than 3 seconds
Steering Wheel during the self-test. A short to ground in the signal return circuit should not set
Audio Switch this DTC, as the reference voltage would fall out-of-range, resulting in DTC
Pack: Circuit / B11BA:1C being set. This DTC applies to the VOL-, VOL+, SEEK-, SEEK+,

Component and MEDIA switches.

Protection
Time-Out
Set by the navigation ACM when the reference voltage to the steering wheel
• B1201:1C â controls is out-of-range. This can be caused by a number of different failures on
Steering Wheel the steering wheel controls circuit except for a stuck switch or a short to ground
Audio Switch in the signal return circuit. This DTC applies to the VOICE and PHONE
Pack 2: Circuit switches.
Voltage Out of
Range
Set by the APIM when the reference voltage to the steering wheel controls is
• B1201:1C â out-of-range. This can be caused by a number of different failures on the steering
Steering Wheel wheel controls circuit except for a stuck switch or a short to ground in the signal
Audio Switch return circuit. This DTC applies to vehicles without navigation.
Pack 2: Circuit
Voltage Out of
Range
Set by the navigation ACM when a steering wheel control switch is detected as
• B1201:63 â active for more than 120 seconds during normal operation, or for any duration
Steering Wheel during the self-test. A short to ground in the signal return circuit should not set
Audio Switch this DTC, as the reference voltage would fall out-of-range, resulting in DTC
Pack 2: Circuit / B1201:1C being set. This DTC applies to the VOICE and PHONE switches.
Component
Protection
Time-Out
Set by the APIM when a steering wheel control switch is detected as active for
• B1201:63 â more than 120 seconds during normal operation, or for any duration during the
Steering Wheel self-test. A short to ground in the signal return circuit should not set this DTC, as
Audio Switch the reference voltage would fall out-of-range, resulting in DTC B1201:1C being
Pack 2: Circuit / set. This DTC applies to vehicles without navigation.
Component
Protection
Time-Out
Set by the non-navigation ACM when the reference voltage to the steering wheel
• B2404 â Audio controls is out-of-range. This can be caused by a number of different failures on
Steering Wheel the steering wheel controls circuit except for a stuck switch or a short to ground
Switch Circuit in the signal return circuit.
Failure

• Clockspring
• ACM
• APIM (without navigation only)

PINPOINT TEST Q: THE STEERING WHEEL CONTROLS ARE INOPERATIVE/DO NOT OPERATE CORRECTLY
NOTE: For vehicles equipped with navigation or not equipped with SYNC, start this pinpoint test at Step Q3.

Q1 CHECK THE SYNCÂ® SYSTEM OPERATION
Yes
NOTE: Carrying out a Master Reset returns all preferenceThe SYNCÂ® system is operating
settings to the factory defaults, erases all the phone book
correctly at this time. CARRY OUT
and call histories, and deletes any devices paired with the
a SYNCÂ® system Master Reset.
SYNC system. REFER to the Owner's Literature.
REVIEW the SYNCÂ® system
• Connect: Multi-Media Interface Tester. operation with the customer. If the
• Using the Multi-Media Interface Tester, test the audio customer device still does not operate
output for the audio input jack, USB port, and Bluetooth correctly, the fault is with the
connection using the VOICE switch on the steering wheel customer device.
controls to enter each mode.
• Do all of the SYNCÂ® inputs function correctly? No
GO to Q2 .
Q2 RESET THE APIM AND RECHECK SYNCÂ®
SYSTEM OPERATION
Yes
• Carry out an APIM power reset by disconnecting the The SYNCÂ® system is operating
battery for 5 minutes, then reconnecting it. correctly at this time. CARRY OUT
• Connect: Multi-Media Interface Tester. a SYNCÂ® system Master Reset.
• Using the Multi-Media Interface Tester, test the audio REFER to the Owner's Literature.
output for the audio input jack, USB port, and Bluetooth
connection using the VOICE switch on the steering wheel REVIEW the SYNCÂ® system
controls to enter each mode. operation with the customer. If the
• Do all of the SYNCÂ® inputs function correctly? customer device still does not operate
correctly, the fault is with the
customer device.
No
GO to Q3 .
Q3 DETERMINE THE INOPERATIVE STEERING
WHEEL CONTROLS
Yes
• Determine which steering wheel controls are inoperative GO to Q4 .
by pressing each steering wheel control switch
individually while operating the audio system in various No
modes (AM/FM, SYNCÂ® (if equipped), etc.). GO to Q5 .
• Is the concern with the VOL-, VOL+, SEEK-, SEEK+,
or MEDIA switch?
Q4 MONITOR THE STEERING WHEEL CONTROL PIDs
(EXCEPT NAVIGATION/SYNCÂ® SWITCHES)
PINPOINT TEST Q: THE STEERING WHEEL CONTROLS ARE INOPERATIVE/DO NOT OPERATE
5803 CORR
• Enter the following diagnostic mode on the scan tool: Yes

ACM DataLogger. GO to Q11 .
• Monitor the steering wheel controls PIDs while pressing
each steering wheel controls switch as follows: No
If only one PID value is incorrect or
the PID value always reads one
particular switch position, INSTALL
new steering wheel controls. REFER
Steering Wheel Controls Switch PID to Steering Wheel Controls in this
VOL- SW_VOLDOWN section. CLEAR any DTCs present.
VOL+ SW_VOLUP operation.
SEEK- SW_SEEKMINUS
SEEK+ SW_SEEKPLUS Otherwise, GO to Q6 .
MEDIA SW_MODE
• Do the PID values agree with the switch positions?

Q5 MONITOR THE STEERING WHEEL CONTROL PIDs
(NAVIGATION/SYNCÂ® SWITCHES)
Yes
• Enter the following diagnostic mode on the scan tool: For vehicles with navigation, GO to
ACM DataLogger (With Navigation) or APIM Q11 .
DataLogger (Without Navigation).
• Monitor the steering wheel controls PIDs while pressing For vehicles without navigation, GO
each steering wheel controls switch as follows: to Q12 .
No
If only one PID value is incorrect or
the PID value always reads one
ACM PIDs particular switch position, INSTALL
new steering wheel controls. REFER
Steering Wheel Controls Switch ACM PID to Steering Wheel Controls in this
VOICE SW_VOICE section. CLEAR any DTCs present.
PHONE SW_PHONE operation.
Otherwise, GO to Q6 .
APIM PIDs
Steering Wheel Controls Switch APIM PID

VOICE SCS_VOICE
PHONE SCS_PHONE
OK SCS_OK
• Do the PID values agree with the switch positions?

Q6 CHECK THE REFERENCE VOLTAGE CIRCUIT TO
THE CLOCKSPRING FOR A SHORT TO VOLTAGE
5804 CORR

• Disconnect: Clockspring C218a. REPAIR the circuit in question.
• Disconnect: ACM C240a or APIM C3338. CLEAR any DTCs present. TEST the
• For a concern with the VOL-, VOL+, SEEK-, SEEK+, or
MEDIA switches, measure the voltage between the No
clockspring C218a-13, circuit VME14 (GY/YE), harness GO to Q7 .
side and ground.
• For a concern with the VOICE, PHONE, or OK switches,

measure the voltage between the clockspring C218a-6,
circuit VME54 (BU/OG), harness side and ground.

Q7 CHECK THE CIRCUITS TO THE CLOCKSPRING
Yes
NOTE: Circuits RME24 (BU/WH) does not need to be GO to Q8 .
checked for a short to ground.
No
• Measure the resistance between the clockspring, harness CLEAR any DTCs present. TEST the
side and the ACM (or APIM ), harness side; and between system for normal operation.
the clockspring, harness side and ground as follows:
Positive
Suspect Meter Negative Meter
Switch Lead Lead Circuit
VOL-, C218a-13 C240a-18, then VME14
VOL+, ground (GY/YE)
SEEK-, C218a-12
SEEK+, or C240a-19, then RME24
MEDIA ground (BU/WH)
5805 CORR
VOICE, C218a-6 C240a-17 (with VME54

PHONE, or navigation) or (BU/OG)
OK C218a-4 C3338-14 (without
navigation), then RME24
ground (BU/WH)
C240a-16 (with
navigation) or
C3338-15 (without
navigation), then
ground

(or APIM ) and the clockspring, and greater than
10,000 ohms between the ACM (or APIM ) and
ground?
Q8 CHECK THE REFERENCE VOLTAGE CIRCUIT TO
THE STEERING WHEEL CONTROLS FOR A SHORT TO
VOLTAGE
Yes
• Ignition OFF. REPAIR the circuit. CLEAR any
• Disconnect: Clockspring C218b. DTCs present. TEST the system for
• Disconnect: Steering Wheel Controls C2997.. normal operation.
• Ignition ON.
• For a concern with the VOL-, VOL+, SEEK-, SEEK+, or No
MEDIA buttons, measure the voltage between the GO to Q9 .
clockspring C218b-10, circuit VME14 (GY/YE), harness
side and ground.
5806 CORR
• For a concern with the VOICE, PHONE, or OK buttons,

measure the voltage between the clockspring C218b-3,
circuit VME54 (BU/OG), harness side and ground.

Q9 CHECK THE CIRCUITS TO THE STEERING WHEEL
CONTROLS FOR AN OPEN OR SHORT TO GROUND
Yes
NOTE: Circuits RME24 (BU/WH) and RME54 GO to Q10 .
(WH/VT) do not need to be checked for a short to ground.
No
• Measure the resistance between the clockspring, harness CLEAR any DTCs present. TEST the
side and the steering wheel controls, harness side; and system for normal operation.
between the clockspring, harness side and ground as
follows:
Negative
Positive Meter
Suspect Switch Meter Lead Lead Circuit
VOL-, VOL+, C218b-10 C2997-2, VME14
SEEK-, SEEK+, then ground (GY/YE)
or MEDIA C218b-11
C2997-4 RME24
(BU/WH)
VOICE, C218a-6 C2997-6, VME54
PHONE, or OK then ground (BU/OG)
C218a-4
C2997-7 RME54
(WH/VT)
• Is the resistance less than 5 ohms between the

clockspring and the steering wheel controls, and
5807 CORR
greater than 10,000 ohms between the clockspring and

ground?
Q10 CHECK THE REFERENCE VOLTAGE CIRCUITS
TO THE CLOCKSPRING
Yes
• Ignition OFF. INSTALL a new clockspring.
• Disconnect: Clockspring C218a. REFER to Section 501-20B .
• Ignition ON. CLEAR any DTCs present. TEST the
• For vehicles without the SYNCÂ® system, measure the system for normal operation.
voltage between the lower clockspring C218a-6, circuit
VME54 (BU/OG) and C218a-12, circuit RME24 No
(BU/WH); and between the lower clockspring C218a-13, INSTALL a new ACM. REFER to
circuit VME14 (GY/YE) and C218a-12, circuit RME24 Audio Control Module (ACM) â
(BU/WH). Fusion or Audio Control Module
(ACM) â MKZ in this section.
operation.
• For vehicles with the SYNCÂ® system, measure the

voltage between the lower clockspring C218a-6, circuit
VME54 (BU/OG) and C218a-4, circuit RME24
(BU/WH); and between the lower clockspring C218a-13,
circuit VME14 (GY/YE) and C218a-12, circuit RME24
(BU/WH).

Q11 CHECK FOR CORRECT ACM OPERATION
Yes
• Connect: All Disconnected Connectors. Audio Control Module (ACM) â
• Disconnect all the ACM connectors. Fusion or Audio Control Module
• Check for: (ACM) â MKZ in this section.
♦ corrosion TEST the system for normal
♦ pushed-out pins
• Connect all the ACM connectors and make sure they seat No
• Operate the system and verify the concern is still present. this time. The concern may have
5808 CORR
connector. CLEAR any DTCs

present.
Q12 CHECK FOR CORRECT APIM OPERATION
Yes
• Connect: All Disconnected Connectors. INSTALL a new APIM . REFER to
• Check for: (APIM) in this section. TEST the
♦ damaged pins
• Connect the APIM connector and make sure it seats The system is operating correctly at
• Wait 2 minutes for the APIM to re-initalize. been caused by a loose or corroded
• Operate the system and verify the concern is still present. connector. CLEAR any DTCs
• Is the concern still present? present.
Pinpoint Test R: The Audio Input Jack Is Inoperative/Does Not Operate Correctly
Normal Operation â Vehicles Without the SYNCÂ® System
Audio signals are sent from the audio input jack to the Audio Front Control Module (ACM). There are no
external power or ground circuits to the audio input jack.
Vehicles With the SYNCÂ® System
Audio signals are sent from the audio input jack to the Accessory Protocol Interface Module (APIM). The
signals are then sent to the ACM . There are no external power or ground circuits to the audio input jack.
• DTC B1D78:13 (Auxiliary Input: Circuit Open) â sets in continuous memory by the navigation
ACM (vehicles without the SYNCÂ® system only) when an open is detected in the audio input jack
circuitry for greater than 250 milliseconds.

• APIM (vehicles with the SYNCÂ® system)
• ACM (vehicles without the SYNCÂ® system)
PINPOINT TEST R: THE AUDIO INPUT JACK IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
NOTE: Before carrying out this pinpoint test, make sure the MP3 device is operating correctly.

R1 CHECK THE AUDIO INPUT JACK AUDIO
Normal Operation â Vehicles Without the SYNCÂ® System 5809

• Connect: Multi-Media Interface Tester . Yes

• Using the Multi-Media Interface Tester, attempt to play The system is operating correctly at this
an audio file using the audio input jack. time. The concern may be with the
• Does the file play correctly? customer device.
No
GO to R2 .
R2 DETERMINE THE VEHICLE CONTENT
Yes
• Determine if the vehicle is equipped with the SYNCÂ® GO to R3 .
system.
• Is the vehicle equipped with the SYNCÂ® system? No
GO to R4 .
R3 CHECK THE APIM AUDIO OUTPUT
Yes
• Using the Multi-Media Interface Tester, attempt to play GO to R4 .
an audio file using either the Universal Serial Bus
(USB) port or Bluetooth. No
• Is the audio output OK for the USB port or GO to Pinpoint Test H .
Bluetooth?
R4 CHECK THE AUDIO INPUT JACK CIRCUITS FOR
A SHORT TO VOLTAGE
Yes
• Disconnect: Audio Input Jack C2401 (Vehicles Without the system for normal operation.
the SYNCÂ® System) or C3337 (Vehicles With the
SYNCÂ® System) . No
• Disconnect: ACM C240c (Vehicles Without the GO to R5 .
SYNCÂ® System) or APIM C3338 (Vehicles With the
SYNCÂ® System) .
• Ignition ON.
• Measure the voltage between the audio input jack,

C2401-1 or C3337-1 Ground
VME46 (BU/GN)
RME46 (WH/GN)
RME45 (YE/GN)
VME45 (BU)
5810

R5 CHECK THE AUDIO INPUT JACK CIRCUITS FOR
AN OPEN OR SHORT TO GROUND
Yes
• Measure the resistance between the audio input jack,
harness side and the ACM (or APIM , if equipped with No
the SYNCÂ® system), harness side; and between the REPAIR the circuit in question. TEST
audio input jack, harness side and ground as follows: the system for normal operation.
Positive Meter
Lead Negative Meter Lead Circuit
C2401-1 or C240c-6 or C3338-47, VME46
C3337-1 then ground (BU/GN)
C2401-2 or C240c-14 or C3338-48, RME46
C3337-2 then ground (WH/GN)
C2401-3 or C240c-8 or C3338-46, RME45
C3337-3 then ground (YE/GN)
C2401-4 or C240c-7 or C3338-45, VME45 (BU)
C3337-4 then ground

input jack and the ACM (or APIM , if equipped with
the SYNCÂ® system), and greater than 10,000 ohms
between the audio input jack and ground?
R6 ISOLATE THE AUDIO INPUT JACK
5811
• Connect: ACM C240c (Vehicles Without the SYNCÂ® Yes

System) or APIM C3338 (Vehicles With the SYNCÂ® The concern was caused by an
System) . inoperative audio input jack. The
• Install a known good audio input jack. Refer to Audio system is operating correctly at this
Input Jack in this section. time.
• Connect: Multi-Media Interface Tester .
• Using the Multi-Media Interface Tester, attempt to play No
an audio file using the audio input jack. For vehicles without the SYNCÂ®
• Does the file play correctly? system, GO to R7 .
For vehicles with the SYNCÂ®

system, GO to R8 .
R7 CHECK FOR CORRECT ACM OPERATION
Yes
♦ corrosion (ACM) â MKZ in this section. TEST
♦ damaged pins the system for normal operation.
♦ pushed-out pins
seat correctly. The system is operating correctly at this
• Operate the system and determine if the concern is still time. The concern may have been
R8 CHECK FOR CORRECT APIM OPERATION
Yes
• Ignition OFF. INSTALL a new APIM . REFER to
♦ damaged pins
• Connect the APIM connector and make sure it seats The system is operating correctly at this
correctly. time. The concern may have been
• Wait 2 minutes for the APIM to re-initialize. caused by a loose or corroded
• Operate the system and determine if the concern is still connector.
present.
Pinpoint Test S: Loud Popping Sound When Cycling The Ignition Switch
Normal Operation
Voltage is sent through the start input circuit to the Audio Front Control Module (ACM) with the ignition in
the START position. Upon receiving this signal, the ACM mutes all speaker outputs to eliminate the
possibility of voltage spikes producing a popping noise through the speakers.
For premium sound, the ACM disables the audio amplifier and subwoofer amplifier while the ignition is in

the START position by keeping the enable circuit voltages below 0.4 volt.
For the SonyÂ® and THXÂ® sound systems, the ACM disables the audio Digital Signal Processing (DSP)
module while the ignition is in the START position by keeping the enable circuit voltage below 0.4 volt.
If there is a short to voltage on any of the enable circuits, distortion is heard in the speakers whenever the
ACM is powered up, and that should be the primary concern addressed. If the speakers have distorted sound,
GO to Symptom Chart - Sound Quality .
• Fuse
• ACM
PINPOINT TEST S: LOUD POPPING SOUND WHEN CYCLING THE IGNITION SWITCH

S1 CHECK THE START INPUT CIRCUIT
VOLTAGE
Yes
• Ignition OFF. INSTALL a new ACM . REFER to Audio Control
• Disconnect: ACM C240a . Module (ACM) â Fusion or Audio Control
• Disconnect: Starter Relay . Module (ACM) â MKZ in this section. TEST the
• Hold the key in the START position. system for normal operation.
• Measure the voltage between the ACM
C240a-15, circuit CBP28 (GY/VT), No
harness side and ground. VERIFY the Smart Junction Box (SJB) fuse 28 (5A)
is OK. If OK, REPAIR the circuit. TEST the system
for normal operation. If not OK, REFER to the
Wiring Diagrams Manual to identify the possible
Pinpoint Test T: The Speed Sensitive Volume Does Not Operate Correctly
Refer to Wiring Diagrams Cell 130 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Audio/Navigation for
Normal Operation
The speed sensitive volume function adjusts the volume based on the Vehicle Speed Sensor (VSS) signal
from the Instrument Panel Cluster (IPC). The IPC does not generate the VSS signal; it gateways the signal
PINPOINT TEST S: LOUD POPPING SOUND WHEN CYCLING THE IGNITION SWITCH 5813
from the PCM. The Smart Junction Box (SJB) also receives this signal and should exhibit symptoms if the
signal is lost.
• Speed sensitive volume setting

• VSS signal concern
• ACM
PINPOINT TEST T: THE SPEED SENSITIVE VOLUME DOES NOT OPERATE CORRECTLY

T1 CHECK THE SPEEDOMETER
OPERATION
Yes
• Drive the vehicle and observe the GO to T2 .
speedometer.
• Does the speedometer operate correctly? No
T2 CHECK THE SPEED SENSITIVE VOLUME
SETTING
Yes
• Turn the speed sensitive volume off. Refer to The system is operating correctly at this time.
the Owner's Literature. INSTRUCT the customer in the correct usage of
• Operate the audio system in radio tuner the speed sensitive volume feature.
(AM/FM) mode.
• Drive the vehicle at various speeds and No
observe the speaker volume. GO to T3 .
• Set the speed sensitive volume to maximum
compensation. Refer to the Owner's Literature.
• Operate the audio system in radio tuner
(AM/FM) mode.
• Drive the vehicle at various speeds and
observe the speaker volume.
• Does the volume remain constant with the
speed sensitive volume turned off, and
increase and decrease with vehicle speed
with the speed sensitive volume set to
maximum?
T3 CHECK FOR DTC U0155 OR DTC U0155:00
Yes
• Using the scan tool, retrieve all continuous GO to Pinpoint Test AG .
DTCs.
• Is DTC U0155 or DTC U0155:00 retrieved No
in any module? GO to T4 .
T4 CHECK FOR CORRECT ACM
OPERATION
Yes
• Disconnect all the ACM connectors. INSTALL a new ACM . REFER to Audio

• Check for: Control Module (ACM) â Fusion or Audio

♦ corrosion Control Module (ACM) â MKZ in this
♦ damaged pins section. TEST the system for normal operation.
♦ pushed-out pins
• Connect all the ACM connectors and make No
sure they seat correctly. The system is operating correctly at this time.
• Operate the system and determine if the The concern may have been caused by a loose or
concern is still present. corroded connector. CLEAR any DTCs present.
Pinpoint Test U: The Audio Does Not Reduce When The Parking Aid Tone Sounds
Normal Operation
The Parking Aid Module (PAM) sends the volume cutback message to the Audio Front Control Module
(ACM) via the Medium Speed Controller Area Network (MS-CAN). When the PAM sounds the parking aid
tone, it broadcasts an enabled message to the ACM . When the ACM receives this message, it reduces the
speaker output so that the parking aid tone can be heard more clearly.
• DTC U0159 (Lost Communication With Parking Assist Control Module ( PAM )) â set by the
non-navigation (Fusion) ACM when the volume cutback message is missing for greater than 5
seconds. When the message is missing, the ACM defaults to no volume cutback when the parking aid
tone is sounding.
• DTC U0159:00 (Lost Communication With Parking Assist Control Module "A": No Sub Type
Information) â set by the non-navigation (MKZ) or the navigation (all) ACM when the volume
cutback message is missing for greater than 5 seconds. When the message is missing, the ACM
defaults to no volume cutback when the parking aid tone is sounding.
• Parking aid system concern

• ACM
PINPOINT TEST U: THE AUDIO DOES NOT REDUCE WHEN THE PARKING AID TONE SOUNDS

U1 CHECK THE PARKING AID SIGNAL
Yes
• Apply the parking brake. GO to U2 .
• Place an object behind the vehicle
within the range of the parking aid No
sensors. Refer to Section 413-13 . REFER to Section 413-13 to continue diagnosis of the
• Ignition ON. parking aid system.
• Place the transmission in REVERSE
(R).
the scan tool: ACM DataLogger .
• Monitor the parking aid input status
PID (RPA_STAT) while the parking
aid tone is sounding.
PINPOINT TEST T: THE SPEED SENSITIVE VOLUME DOES NOT OPERATE CORRECTLY 5815
• Does the PID read "Enabled" when

the parking aid tone is sounding?
U2 CHECK FOR CORRECT ACM
OPERATION
Yes
• Disconnect all the ACM connectors. INSTALL a new ACM . REFER to Audio Control
• Check for: Module (ACM) â Fusion or Audio Control Module
♦ corrosion (ACM) â MKZ in this section. TEST the system for
♦ pushed-out pins
• Connect all the ACM connectors and No
make sure they seat correctly. The system is operating correctly at this time. The
• Operate the system and verify the concern may have been caused by a loose or corroded
concern is still present. connector.
Pinpoint Test V: Voice Recognition Is Inoperative/Does Not Operate Correctly
Normal Operation â Vehicles Without Navigation
When the VOICE switch is pressed, it changes a reference voltage signal, and the audio system enters voice
recognition mode. The VOICE switch is wired to the Accessory Protocol Interface Module (APIM).
Vehicles With Navigation
When the VOICE switch is pressed, it changes a reference voltage signal, and the audio system enters voice
recognition mode. The VOICE switch is wired to the Audio Front Control Module (ACM). The APIM
receives the microphone input and also broadcasts it to the ACM . The first voice commands spoken
determine which system handles the voice commands.
The microphone test is available through the scan tool or through the ACM self-diagnostic mode. Running
this test causes the ACM to produce a test tone. If the system is operating correctly, the microphone detects
the tone and produces a signal to the ACM indicating the tone was heard.
• DTC B1A16:01 (Microphone Input Circuit: General Electrical Failure) â set by the APIM during
the on-demand self-test if it does not detect the microphone.
• DTC B1D79:01 (Microphone Input Circuit: General Electrical Failure) â set by the ACM during
the microphone test when it does not receive an adequate signal from the microphone when the test
tone is sounded.

• Microphone
• ACM (if equipped with navigation)
• APIM (if equipped)
PINPOINT TEST U: THE AUDIO DOES NOT REDUCE WHEN THE PARKING AID TONE SOUNDS
5816
PINPOINT TEST V: VOICE RECOGNITION IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
Section 414-01 .

V1 CHECK THE OPERATION OF THE STEERING
WHEEL CONTROLS
Yes
• Operate the audio system in radio tuner (AM/FM) GO to V2 .
mode.
• Press the VOICE switch on the steering wheel controls. No
• Does the audio system enter voice recognition mode? GO to Pinpoint Test Q to diagnose the
steering wheel controls system.
V2 CHECK THE OPERATION OF THE VOICE
RECOGNITION
Yes
• Press the VOICE switch on the steering wheel controls. If the vehicle is equipped with
• Wait for the audio system to acknowledge the VOICE navigation, GO to V3 .
switch being pressed.
• While still in voice recognition mode, speak the Otherwise, the system is operating
command "PHONE", and observe the audio system. correctly at this time. ADVISE the
• Does the audio system acknowledge the command customer on the correct operation of
"PHONE"? the voice recognition system.
No
GO to V6 .
V3 CHECK THE MICROPHONE SIGNAL TO THE
ACM
Yes
• Operate the audio system in radio tuner (AM/FM) GO to V13 .
mode.
• Disconnect: ACM C240c. No
• NOTE: ACM C240c must be disconnected after the GO to V4 .
ACM is powered on or the ACM will not receive the
RUN message over the network.
• Press the VOICE switch on the steering wheel controls.
• While speaking a command, measure the AC voltage
between the ACM C240c-11, circuit VMM13 (YE/GN),
harness side and the ACM C240c-12, circuit RMM13
(BU), harness side.

5817

V4 CHECK THE MICROPHONE CIRCUITS TO THE
ACM FOR A SHORT TO VOLTAGE
Yes
• Disconnect: APIM C3338. the system for normal operation.
• Ignition ON.
• Measure the voltage between the ACM C240c-11, No
circuit VMM13 (YE/GN), harness side and ground; and GO to V5 .
between the ACM C240c-12, circuit RMM13 (BU),

V5 CHECK THE MICROPHONE CIRCUITS TO THE
ACM FOR AN OPEN OR SHORT TO GROUND
Yes
• Ignition OFF. GO to V9 .
• Measure the resistance between the ACM C240c-11,
circuit VMM13 (YE/GN), harness side and the APIM No
C3338-12, circuit VMM13 (YE/GN), harness side; and REPAIR the circuit in question. TEST
between the ACM C240c-11, circuit VMM13 (YE/GN), the system for normal operation.
• Measure the resistance between the ACM C240c-12,

circuit RMM13 (BU), harness side and the APIM
C3342-13, circuit RMM13 (BU), harness side; and
between the ACM C240c-12, circuit RMM13 (BU),

5818

and the APIM , and greater than 10,000 ohms
between the ACM and ground?
V6 CHECK THE MICROPHONE CIRCUITS FOR AN
OPEN
Yes
• Disconnect: Microphone C9045.
• Disconnect: APIM C3338. No
• Measure the resistance between the microphone, REPAIR the circuit in question. TEST
harness side and between the APIM , harness side as the system for normal operation.
follows:

Lead Lead Circuit
C9045-1 C3338-18 RMM13 (BU)
C9045-2 C3338-5 VMM13
(YE/GN)
C9045-3 C3338-6 DMM13 (none)

V7 CHECK THE MICROPHONE SHIELD
Yes
• Disconnect: Negative Battery Cable. CONNECT the negative battery cable.
• Measure the resistance between the microphone GO to V8 .
C9045-3, circuit DMM13 (none), harness side and
ground. No
REPAIR the circuit for an open. TEST

5819

V8 CHECK THE MICROPHONE CIRCUITS FOR A
SHORT TO GROUND
Yes
• Measure the resistance between the microphone
C9045-1, circuit RMM13 (BU), harness side and No
ground; and between the microphone C9045-2, circuit REPAIR the circuit in question. TEST
VMM13 (YE/GN), harness side and ground. the system for normal operation.

V9 CHECK THE MICROPHONE SIGNAL CIRCUIT
Yes
• Measure the voltage between the microphoneC9045-2, REPAIR the circuit in question. TEST
circuit VMM13 (YE/GN), harness side and ground. the system for normal operation.
No
GO to V10 .

V10 CHECK THE MICROPHONE VOLTAGE SUPPLY
CIRCUIT
Yes
• Connect: APIM C3338. GO to V11 .
• Ignition ON.
• Measure the voltage between the microphone C9045-1, No
circuit RMM13 (BU), harness side and ground. GO to V12 .

5820

V11 ISOLATE THE MICROPHONE
Yes
• Connect: APIM C3342. The fault was caused by an inoperative
• Install a new microphone. Refer to Microphone in this microphone. The system is now
section. operating correctly.
mode. No
• Press the VOICE switch on the steering wheel controls GO to V12 .
and attempt several voice commands.
• Does the voice recognition operate correctly?
V12 CHECK FOR CORRECT APIM OPERATION
Yes
• Connect: All Disconnected Connectors. INSTALL a new APIM . REFER to
♦ damaged pins
• Connect the APIM connector and make sure it seats The system is operating correctly at
• Wait 2 minutes for the APIM to re-initalize. caused by a loose or corroded
V13 CHECK FOR CORRECT ACM OPERATION
Yes
♦ damaged pins (ACM) â MKZ in this section.
♦ pushed-out pins TEST the system for normal operation.
seat correctly. No
• Operate the system and verify the concern is still The system is operating correctly at
present. this time. The concern may have been
connector.
Pinpoint Test W: No Global Positioning System (GPS) Antenna Signal
Normal Operation
The Global Positioning System (GPS) antenna provides information from the GPS satellite system to the
Audio Front Control Module (ACM). This information is used to calculate position and direction of travel.
A splitter is used in the front satellite radio antenna cable to split the signals between the satellite radio and the

GPS . It is possible that a concern in the GPS signal line after the splitter may cause a navigation system
concern without affecting the satellite radio.
• DTC B119F:01 ( GPS Antenna: General Electrical Failure) â sets when any failure is detected in
the GPS antenna circuit.
• DTC B119F:13 ( GPS Antenna: Circuit Open) â sets when an open is detected in the GPS antenna
circuit.

• AM/FM/SDARS/NAV radio antenna
• ACM
PINPOINT TEST W: NO GPS ANTENNA SIGNAL

W1 CHECK THE SATELLITE
SIGNAL PID (SAT_SIG_STR)
Yes
• Enter the following diagnostic GO to Pinpoint Test B .
mode on the scan tool: ACM
DataLogger . No
• Monitor the ACM PID GO to W2 .
(SAT_SIG_STR).
• Does the PID indicate "No
Signal"?
W2 CHECK FOR GPS
SIGNAL-RELATED DTCs
Yes
• Clear the ACM DTCs. INSTALL a new front satellite radio antenna cable. REFER
• Carry out the ACM self-test. to Antenna Cable â Satellite Radio in this section.
• Is DTC B119F:01 or DTC CLEAR the DTCs. TEST the system for normal operation.
B119F:13 retrieved?
No
GO to W3 .
W3 SUBSTITUTE KNOWN GOOD
ANTENNA
Yes
• Ignition OFF. GO to W4 .
• Install a known good
AM/FM/SDARS/NAV antenna. No
Antenna â AM/FM/Satellite INSTALL a new AM/FM/SDARS/NAV radio antenna.
Radio/Navigation . REFER to Antenna â AM/FM/Satellite Radio/Navigation
• Is the concern still present? in this section. TEST the system for normal operation.
W4 CHECK FOR CORRECT ACM
OPERATION
Yes
• Disconnect all the ACM (ACM) â Fusion or Audio Control Module (ACM) â
PINPOINT TEST W: NO GPS ANTENNA SIGNAL 5822

connectors. MKZ in this section. TEST the system for normal operation.
• Check for:
♦ corrosion No
♦ damaged pins The system is operating correctly at this time. The concern
♦ pushed-out pins may have been caused by a loose or corroded connector.
• Connect all the ACM connectors CLEAR any DTCs present.
and make sure they seat correctly.
• Operate the system and verify the
Pinpoint Test X: The Position Cursor Is Inaccurate
Normal Operation
The primary source of vehicle location for the navigation system is the Audio Front Control Module (ACM)
receiving the position signal through the Global Positioning System (GPS) antenna (integral to the satellite
radio antenna).
In addition, the ACM receives the navigation rolling wheel count signal from the Instrument Panel Cluster
(IPC) (which gateways the signal from the ABS module). This secondary signal is used to calculate vehicle
position when the GPS signal is lost. It also supports the adaptive learning function of the ACM , whereby the
ACM can compensate for long-term differences between the GPS signal location and the actual distance
traveled by the vehicle.
If DTC B119F:01 or DTC B119F:13 is present, GO to Pinpoint Test W to diagnose a concern with the GPS
antenna.
• DTC U2014:09 (Control Module Hardware: Component Failure) â sets when the ACM detects a
fault in the internal gyroscope. The gyroscope is not serviceable.
• GPS antenna concern

• Network message concern
• ACM
PINPOINT TEST X: THE POSITION CURSOR IS INACCURATE

X1 CHECK THE ACM FOR GPS
SIGNAL-RELATED DTCs
Yes
• Retrieve the ACM GO to Pinpoint Test W .
continuous DTCs.
• Is DTC B119F:01 or DTC No
B119F:13 present? GO to X2 .
X2 CHECK FOR DTC U0155:00
Yes
• Review the ACM continuous GO to Pinpoint Test AG .

DTCs.
• Is DTC U0155:00 present? No
GO to X3 .
X3 CHECK FOR CORRECT
ACM OPERATION
Yes
• Disconnect all the ACM (ACM) â Fusion or Audio Control Module (ACM) â MKZ
connectors. in this section. TEST the system for normal operation.
• Check for:
♦ corrosion No
♦ damaged pins The system is operating correctly at this time. The concern may
♦ pushed-out pins have been caused by a loose or corroded connector. CLEAR any
• Connect all the ACM DTCs present.
connectors and make sure
they seat correctly.
verify the concern is still
present.
Pinpoint Test Y: The Voice Guidance Is Inoperative/Does Not Operate Correctly
Normal Operation â Premium Sound
The voice-assisted route guidance is broadcast through the front speakers. The voice guidance volume can be
adjusted using the settings on the Audio Front Control Module (ACM).
SonyÂ® or THXÂ® Sound
The voice-assisted route guidance is broadcast through the instrument panel speaker. The volume can be
adjusted using the settings on the ACM . The ACM sends the voice guidance audio signals to the audio
Digital Signal Processing (DSP) module through a dedicated pair of circuits.
• DTC B1A07:01 (Speaker #7: General Electrical Failure) â sets when a fault is detected in the
navigation audio circuits.
• Incorrect voice guidance setting

• Wiring, terminals or connectors (except premium sound)
• Audio DSP module (except premium sound)
• ACM
PINPOINT TEST Y: THE VOICE GUIDANCE IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
PINPOINT TEST X: THE POSITION CURSOR IS INACCURATE 5824


Y1 CHECK THE VOICE GUIDANCE SETTING
Yes
• Adjust the voice volume to approximately 50%. Refer to The concern was caused by an
the Owner's Literature. incorrect customer setting.
• Set a destination and start the route using the navigation INSTRUCT the customer in the
controls. Refer to the Owner's Literature. correct use of the voice guidance
• Observe the voice guidance. feature.
• Does the voice guidance operate correctly?
No
GO to Y2 .
Y2 CHECK THE SPEAKER OUTPUT
Yes
• Carry out the speaker walk test. Refer to Audio Control For premium sound, GO to Y6 .
• Do the front speakers (premium sound) or instrument For SonyÂ® or THXÂ® sound, GO
panel speaker (SonyÂ® or THXÂ® sound) operate to Y3 .
correctly?
No
For premium sound, GO to Pinpoint
Test D .
For SonyÂ® sound, GO to Pinpoint

Test E .
For THXÂ® sound, GO to Pinpoint

Test F .
Y3 CHECK THE NAVIGATION AUDIO SIGNAL TO THE
AUDIO DSP MODULE
Yes
• Ignition OFF. GO to Y7 .
• Disconnect: Audio DSP Module 4240c (SonyÂ®) Or
C4235c (THXÂ®) . No
• Operate the audio system in navigation mode. GO to Y4 .
• For SonyÂ® sound, while pressing the REPEAT button on
the ACM , measure the AC voltage between the audio
DSP module C4240c-4, circuit VMN07 (GY), harness side
and the audio DSP module C4240c-14, circuit RMN07
(VT), harness side.
• For THXÂ® sound, while pressing the REPEAT button on

the ACM , measure the AC voltage between the audio
DSP module C4235c-6, circuit VMN07 (GY), harness side
and the audio DSP module C4235c-16, circuit RMN07

5825
(VT), harness side.

Y4 CHECK THE NAVIGATION AUDIO SIGNAL
Yes
• Disconnect: ACM C240a . TEST the system for normal
• For SonyÂ® sound, measure the voltage between the
audio DSP module C4240c-4, circuit VMN07 (GY), No
harness side and ground; and between the audio DSP GO to Y5 .
module C4240c-14, circuit RMN07 (VT), harness side and
ground.
• For THXÂ® sound, measure the voltage between the

audio DSP module C4235c-6, circuit VMN07 (GY),
harness side and ground; and between the audio DSP
module C4235c-16, circuit RMN07 (VT), harness side and
ground.

Y5 CHECK THE NAVIGATION AUDIO SIGNAL
CIRCUITS FOR AN OPEN OR SHORT TO GROUND

5826

• Measure the resistance between the audio DSP module, GO to Y6 .
harness side and the ACM , harness side; and between the
audio DSP module, harness side and ground as follows: No
operation.
Sound Positive Meter Negative

System Lead Meter Lead Circuit
SonyÂ® C4240c-4, then C240a-2 VMN07
ground (GY)
C4240c-14, then C240a-14 RMN07
ground (VT)
THXÂ® C4235c-6, then C240a-2 VMN07
ground (GY)
C4235c-16, then C240a-14 RMN07
ground (VT)

DSP module and the ACM , and greater than 10,000
ohms between the audio DSP module and ground?
Y6 CHECK FOR CORRECT ACM OPERATION
Yes
♦ damaged pins (ACM) â MKZ in this section.
♦ pushed-out pins TEST the system for normal
• Connect all the ACM connectors and make sure they seat operation after the repair.
correctly.
• Operate the system and verify the concern is still present. No
• Is the concern still present? The system is operating correctly at
this time. The concern may have
connector.

5827
Y7 CHECK FOR CORRECT AUDIO DSP MODULE

OPERATION
Yes
• Disconnect all the audio DSP module connectors. INSTALL a new audio DSP module.
• Check for: REFER to Audio Digital Signal
♦ corrosion Processing (DSP) Module in this
♦ damaged pins section. TEST the system for normal
• Connect all the audio DSP module connectors and make
sure they seat correctly. No
• Is the concern still present? this time. The concern may have
connector.
Pinpoint Test Z: The SYNCÂ® System Is Completely Inoperative
Normal Operation
When a button on the Front Controls Interface Module (FCIM) is pressed, a network message is sent to the
Accessory Protocol Interface Module (APIM) via the Medium Speed Controller Area Network (MS-CAN).
The APIM takes the appropriate action and sends a status message to the Front Display Interface Module
(FDIM) (vehicles without navigation) or the Audio Front Control Module (ACM) (vehicles with navigation)
in order to update the display screen.
• DTC U3000:04 (Control Module: System Internal Failure) â sets when the APIM detects a fault
due to a device conflict or an internal failure.
• Audio system concern

• Customer error
• Customer device
• APIM
PINPOINT TEST Z: THE SYNCÂ® SYSTEM IS COMPLETELY INOPERATIVE

Z1 CHECK FOR SCAN TOOL
COMMUNICATION WITH THE APIM
Yes
• Carry out the network test using the GO to Z2 .
scan tool.
• Does the APIM pass the network No
test? REFER to Section 418-00 .
Z2 CHECK THE SYNCÂ® SYSTEM
OPERATION
Yes
The SYNCÂ® system is operating correctly at this time.

NOTE: Carrying out a Master Reset CARRY OUT a SYNCÂ® system Master Reset. Refer
returns all preference settings to the to the Owner's Literature.
factory defaults, erases all the phone
book and call histories, and deletes any REVIEW the SYNCÂ® system operation with the
devices paired with the SYNCÂ® customer. If the customer device still does not operate
system. correctly, the fault is with the customer device.
• Connect: Multi-Media Interface Tester. No

• Using the Multi-Media Interface GO to Z3 .
Tester, test the audio output for the
audio input jack, USB port, and
Bluetooth connection using the VOICE
switch on the steering wheel controls to
enter each mode.
• Do all of the SYNCÂ® inputs
function correctly?
Z3 RESET THE APIM AND RECHECK
SYNCÂ® SYSTEM OPERATION
Yes
• Carry out an APIM power reset by The SYNCÂ® system is operating correctly at this time.
disconnecting the battery for 5 minutes, CARRY OUT a SYNCÂ® system Master Reset.
then reconnecting it. REFER to the Owner's Literature.
• Connect: Multi-Media Interface Tester.
• Using the Multi-Media Interface REVIEW the SYNCÂ® system operation with the
Tester, test the audio output for the customer. If the customer device still does not operate
audio input jack, USB port, and correctly, the fault is with the customer device.
Bluetooth connection using the VOICE
switch on the steering wheel controls to No
enter each mode. If only some (but not all) of the inputs are inoperative,
• Do all of the SYNCÂ® inputs GO to Symptom Chart - SYNCÂ®System to diagnose
function correctly? the observed symptom. If all inputs are inoperative
and/or DTC U3000:04 is present, INSTALL a new
APIM . REFER to Accessory Protocol Interface Module
(APIM) in this section.
Pinpoint Test AA: Unable To Pair Bluetooth Device
Normal Operation
When a new Bluetooth device is added, the Accessory Protocol Interface Module (APIM) and the Bluetooth
device must be paired together. Most Bluetooth devices can pair with the SYNCÂ® system, although
functionality may vary. To determine if a Bluetooth device is supported, retrieve the Consumer Interface
Processor (CIP) software level using the Accessory Protocol Interface Module (APIM) Software Level Check
in this section, and verify the customer device is on the compatibility list for the current CIP software level.
Pairing a Bluetooth device is accomplished through the "Add Device" selection of the phone menu. When
pairing a device, the SYNCÂ® system generates a unique Personal Identification Number (PIN) that must be
entered on the Bluetooth device in order for the pairing process to be successful. There are also some
device-specific actions that must take place. For additional information on the pairing process, refer to the
Owner's Literature.
PINPOINT TEST Z: THE SYNCÂ® SYSTEM IS COMPLETELY INOPERATIVE 5829

• Incompatible Bluetooth device
• Customer error
• Customer Bluetooth device
• APIM
PINPOINT TEST AA: UNABLE TO PAIR BLUETOOTH DEVICE

AA1 CHECK THE BLUETOOTH CONNECTION
Yes
NOTE: Carrying out a Master Reset returns all The SYNCÂ® system is operating
preference settings to the factory defaults, erases all correctly at this time. CARRY OUT a
the phone book and call histories, and deletes any SYNCÂ® system Master Reset. REFER to
devices paired with the SYNCÂ® system. the Owner's Literature.
• Connect: Multi-Media Interface Tester . REVIEW the pairing process with the
• Using the Multi-Media Interface Tester, connect to customer. If the customer device still does
the SYNCÂ® system using Bluetooth. Follow the not pair, the fault is with the customer
tool instructions. device.
tool: APIM DataLogger . No
• Monitor the Bluetooth device paired PID GO to AA2 .
(BT_PAIR) and the Bluetooth device connected PID
(BT_CONN).
• Do the PIDs BT_PAIR and BT_CONN both read
"Yes"?
AA2 CHECK FOR CORRECT APIM OPERATION
Yes
• Disconnect the APIM connector. INSTALL a new APIM . REFER to
• Check for: Accessory Protocol Interface Module
♦ corrosion (APIM) in this section. TEST the system
♦ damaged pins for normal operation.
♦ pushed-out pins
• Wait 2 minutes for the APIM to re-initalize. time. The concern may have been caused
present.
Pinpoint Test AB: The Universal Serial Bus (USB) Port Is Inoperative/Does Not Operate Correctly
Normal Operation
The Universal Serial Bus (USB) port is connected to the Accessory Protocol Interface Module (APIM)
through the USB cable. The USB port can be used to play audio files or upload software from mass storage
devices, or for connecting a media device.
If supported by the user device, the USB can provide charging. Because of this feature, when a USB device is
plugged into the USB port, the SYNCÂ® system does not automatically switch to the device.

If a USB mass storage device is used to play an audio file, the SYNCÂ® system only plays audio files that do
not have Digital Rights Management (DRM) protection.
The USB cable and port are not serviceable separately.
• DTC B1252:04 (USB Port: System Internal Failure) â sets when the APIM detects an
over-temperature condition in the USB circuit. This can be caused by a fault in the USB cable and
port, or by the customer USB device.
• DTC B1252:11 (USB Port: Circuit Short to Ground) â sets when the APIM detects an over-current
condition in the USB circuit. This can be caused by a fault in the USB cable and port, or by the
customer USB device.
• Customer USB device

• USB cable and port
• APIM
PINPOINT TEST AB: THE USB PORT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

AB1 CHECK THE USB CONNECTION
Yes
• Connect: Multi-Media Interface The SYNCÂ® system is operating correctly. REVIEW the
Tester. operation of the USB port with the customer. If the
• Using the Multi-Media Interface customer device still does not operate correctly, the fault is
Tester, attempt to play a file using with the customer device.
the USB port.
• Does the audio file play No
successfully using the USB GO to AB2 .
connection?
AB2 INSPECT THE USB CABLE
Yes
• Ignition OFF. The concern was caused by the USB connection not being
• Disconnect: USB Cable At APIM . seated correctly. The system is now operating correctly.
• Inspect the USB cable for damage.
• Connect: USB Cable At APIM . No
• Ignition ON. GO to AB3 .
• Connect: Multi-Media Interface
Tester.
• Using the Multi-Media Interface
Tester, attempt to play a file using
the USB port.
• Does the audio file play
successfully using the USB
connection?
AB3 RESET THE APIM AND
RECHECK SYNCÂ® SYSTEM
OPERATION
Yes
The SYNCÂ® system is operating correctly at this time.

NOTE: Carrying out a Master Reset CARRY OUT a SYNCÂ® system Master Reset. REFER
returns all preference settings to the to the Owner's Literature.
factory defaults, erases all the phone
book and call histories, and deletes REVIEW the SYNCÂ® system operation with the
any devices paired with the customer. If the customer device still does not operate
SYNCÂ® system. correctly, the fault is with the customer device.
• Carry out an APIM power reset by No

disconnecting the battery for 5 If only the USB port is inoperative, GO to AB4 . If
minutes, then reconnecting it. additional inputs are inoperative, GO to Symptom Chart -
• Connect: Multi-Media Interface SYNCÂ®System to diagnose the observed symptom. If all
Tester. inputs are inoperative, INSTALL a new APIM . REFER to
• Using the Multi-Media Interface Accessory Protocol Interface Module (APIM) in this
Tester, test the audio output for the section.
audio input jack, USB port, and
Bluetooth connection using the
VOICE switch on the steering wheel
controls to enter each mode.
• Do all of the SYNCÂ® inputs
function correctly?
AB4 ISOLATE THE USB CABLE AND
PORT
Yes
• Install a new USB cable and port. The concern was caused by an inoperative USB cable. The
Refer to Universal Serial Bus (USB) system is now operating correctly.
Cable and Port in this section.
• Connect: Multi-Media Interface No
Tester. GO to AB5 .
• Using the Multi-Media Interface
Tester, attempt to play a file using
the USB port.
• Does the audio file play
successfully using the USB
connection?
AB5 CHECK FOR CORRECT APIM
OPERATION
Yes
• Disconnect the APIM connector. INSTALL a new APIM . REFER to Accessory Protocol
• Check for: Interface Module (APIM) in this section. TEST the system
♦ damaged pins
• Connect the APIM connector and The system is operating correctly at this time. The concern
• Wait 2 minutes for the APIM to CLEAR any DTCs present.
re-initalize.
Pinpoint Test AC: The SYNCÂ® System Audible Prompts Are Inoperative/Do Not Operate Correctly
PINPOINT TEST AB: THE USB PORT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY5832
Normal Operation
The Text-To-Speech (TTS) and voice prompt features speak certain text information and interaction requests
in order to minimize driver distraction while driving. The ringtone alerts the driver to an incoming call.
Audible prompts can range from a simple tone to more elaborate spoken text, based on the customer setting.
When interaction mode is set to standard, detailed guidance is provided. When interaction mode is set to
advanced, most prompts are tones only and minimal audible guidance is provided. Refer to the Owner's
Literature for further information on voice interaction.
The audio signals for the TTS and voice prompt features, the ringtones, and audio from the outside device
during a phone call, are sent from the Accessory Protocol Interface Module (APIM) to the Audio Front
Control Module (ACM).
• Customer setting
• ACM
• APIM
PINPOINT TEST AC: THE SYNCÂ® SYSTEM AUDIBLE PROMPTS ARE INOPERATIVE/DO NOT OPERATE
CORRECTLY

AC1 CHECK THE AUDIBLE PROMPT SETTING
Yes
• Operate the audio system in SYNCÂ® mode. The system is operating
• Verify the audible prompts are enabled. Refer to "SYNCÂ® Voice correctly at this time. The
Recognition Feature" in the Owner's Literature. concern was caused by a
• Press the VOICE switch on the steering wheel controls and customer setting.
observe the SYNCÂ® system audible prompt. INSTRUCT the customer in
• Does the SYNCÂ® system produce an audible prompt the correct operation of the
correctly? audible prompt feature.
No
GO to AC2 .
AC2 CHECK FOR A VOLTAGE SIGNAL FROM THE APIM
Yes
NOTICE: This pinpoint test step directs testing circuits using a For vehicles with
back-probe method. Use the special back-probe tool specified navigation, GO to Pinpoint
in the tool list in this section. Do not force test leads or other Test Y .
probes into connectors. Adequate care must be exercised to
avoid connector terminal damage while ensuring that good Otherwise, GO to AC6 .
electrical contact is made with the circuit or terminal. Failure
to follow these instructions may cause damage to wiring, No

terminals, or connectors and subsequent electrical faults. GO to AC3 .
• Operate the audio system in SYNCÂ® mode.

• While pressing the VOICE switch repeatedly, measure the AC
voltage by back-probing between the ACM C240c-4, circuit
VMN14 (WH/VT), harness side and the ACM C240c-5, circuit
RMN14 (GY/BN), harness side.
• Is an AC voltage produced each time the VOICE switch is
pressed?
AC3 CHECK THE AUDIBLE PROMPT CIRCUITS FOR A
SHORT TO VOLTAGE
Yes
• Ignition OFF. REPAIR the circuit in
• Disconnect: ACM C240c . question. TEST the system
• Disconnect: APIM C3338 . for normal operation.
• Ignition ON.
• Measure the voltage between the APIM C3338-3, circuit VMN14 No
(WH/VT), harness side and ground; and between the APIM GO to AC4 .
C3338-4, circuit RMN14 (GY/BN), harness side and ground.

AC4 CHECK THE AUDIBLE PROMPT CIRCUITS FOR AN
Yes
• Measure the resistance between the APIM C3338-3, circuit
VMN14 (WH/VT), harness side and the ACM 240c-4, circuit No
VMN14 (WH/VT), harness side; and between the APIM C3338-3, REPAIR the circuit in
circuit VMN14 (WH/VT), harness side and ground. question. TEST the system
• Measure the resistance between the APIM C3338-4, circuit

RMN14 (GY/BN), harness side and the ACM 240c-5, circuit
RMN14 (GY/BN), harness side; and between the APIM C3338-4,
circuit RMN14 (GY/BN), harness side and ground.
PINPOINT TEST AC: THE SYNCÂ® SYSTEM AUDIBLE PROMPTS ARE INOPERATIVE/DO NOT
5834OPERA
• Is the resistance less than 5 ohms between the APIM and the
ACM , and greater than 10,000 ohms between the APIM and
ground?
AC5 CHECK FOR CORRECT APIM OPERATION
Yes
• Connect: All Disconnected Connectors . INSTALL a new APIM .
• Disconnect the APIM connector. REFER to Accessory
• Check for: Protocol Interface Module
♦ corrosion (APIM) in this section.
• Connect the APIM connector and make sure it seats correctly.
• Wait 2 minutes for the APIM to re-initalize. No
• Is the concern still present? The system is operating
corroded connector.
AC6 CHECK FOR CORRECT ACM OPERATION
Yes
• Ignition OFF. INSTALL a new ACM .
• Disconnect all the ACM connectors. REFER to Audio Control
• Check for: Module (ACM) â Fusion
♦ corrosion or Audio Control Module
♦ damaged pins (ACM) â MKZ in this
♦ pushed-out pins section. TEST the system
• Connect all the ACM connectors and make sure they seat correctly. for normal operation.
corroded connector.
Pinpoint Test AD: DTC U0100:00
Normal Operation
The Accessory Protocol Interface Module (APIM) receives network messages from the PCM via the High
Speed Controller Area Network (HS-CAN). These messages include the odometer reading and the fuel level.
As other modules outside of the audio system also receive these messages, all modules receiving a particular
message should exhibit a symptom if the message is missing.

• DTC U0100:00 (Lost Communication With ECM /PCM "A": No Sub Type Information) â set by
the APIM when it is missing messages from the PCM over the HS-CAN for greater than 5 seconds
with the ignition in the RUN position.

• PCM
PINPOINT TEST AD: DTC U0100:00

AD1 CHECK FOR LOST
COMMUNICATION DTCs
Yes
• Clear continuous DTCs from all
modules. No
• Ignition OFF. The system is operating correctly at this time. The DTC may
• Ignition ON. have been set due to an intermittent fault in the network
• Wait at least 10 seconds. wiring.
• Retrieve all continuous DTCs from
all modules.
• Is DTC U0100 or DTC U0100:00
set in any modules?
AD2 CHECK FOR BATTERY
VOLTAGE OUT-OF-RANGE DTCs
Yes
• Carry out the self-test for the For the APIM , REFER to DTC Charts in this section.
following modules:
♦ APIM For all other modules, REFER to the master list in Section
♦ PCM 419-10 .
♦ Instrument Panel Cluster
(IPC) No
• Is DTC B1317, B1318, U3003:16, GO to AD3 .
or U3003:17 recorded in any
module?
AD3 CHECK FOR DTC U0100 OR
DTC U0100:00 SET IN MULTIPLE
MODULES
Yes
• Review the recorded results from GO to AD4 .
the self-test.
• Is DTC U0100 or DTC U0100:00 No
set in more than one module? If there is an observable symptom, GO to Symptom Chart -
General Audio System to diagnose the observed symptom.
If there is no observable symptom, CHECK the wiring

between the APIM and the PCM for an intermittent fault.
AD4 CHECK FOR CORRECT PCM
OPERATION
PINPOINT TEST AD: DTC U0100:00 5836

• Disconnect all the PCM Yes

connectors. INSTALL a new PCM. Refer to the appropriate section in
• Check for: Group 303 for the procedure.. CLEAR all continuous DTCs.
♦ corrosion REPEAT the APIM self-test.
♦ damaged pins
• Connect all the PCM connectors The system is operating correctly at this time. The concern
and make sure they seat correctly. may have been caused by a loose or corroded connector.
• Is the concern still present? CLEAR all continuous DTCs. REPEAT the APIM self-test.
Pinpoint Test AE: DTC U0140 Or DTC U0140:00
Normal Operation
Several audio system modules receive network messages from the Smart Junction Box (SJB) via the Medium
Speed Controller Area Network (MS-CAN). The following information is included in the messages:
• Ignition switch position

• Illumination dimmer control
• Accessory delay status
As more than one module receives these messages, all modules receiving a particular message should exhibit
a symptom if the message is missing.
• DTC U0140 (Lost Communication With Body Control Module ( GEM )) â set by the
non-navigation (Fusion) Audio Front Control Module (ACM), the Front Controls Interface Module
(FCIM) (Fusion), or the Front Display Interface Module (FDIM) when network messages are missing
from the SJB for greater than 5 seconds with the ignition in RUN.
• DTC U0140:00 (Lost Communication With Body Control Module: No Sub Type Information) â
set by the non-navigation (MKZ) or navigation (all) ACM , the audio Digital Signal Processing (DSP)
module, the Accessory Protocol Interface Module (APIM), the Global Positioning System Module
(GPSM), or the FCIM (MKZ) when network messages are missing from the SJB for greater than 5

• SJB
PINPOINT TEST AE: DTC U0140 OR DTC U0140:00

AE1 CHECK FOR LOST
COMMUNICATION DTCs
Yes

• Clear continuous DTCs from No

all modules. The system is operating correctly at this time. The DTC may
• Ignition OFF. have been set due to an intermittent fault in the network wiring.
• Ignition ON.
• Wait at least 10 seconds.
• Retrieve all continuous DTCs
from all modules.
• Is DTC U0140 or DTC
U0140:00 set in any audio
system module?
AE2 CHECK FOR BATTERY
Yes
• Carry out the self-test for the For an audio system module, REFER to DTC Charts in this
following modules: section.
♦ ACM
♦ Audio DSP module (if For the SJB , REFER to Section 419-10 .
equipped)
♦ APIM (if equipped) No
♦ FCIM GO to AE3 .
♦ FDIM
♦ GPSM (if equipped)
♦ SJB
• Is DTC B1317, B1318,
U3003:16, or U3003:17
recorded in any module?
AE3 CHECK FOR DTC U0140 OR
DTC U0140:00 SET IN MULTIPLE
MODULES
Yes
• Review the recorded results GO to AE4 .
from the self-test.
• Is DTC U0140 or DTC No
U0140:00 set in more than If there is an observable symptom, GO to Symptom Chart -
one audio system module? General Audio System to diagnose the observed symptom.
If there is no observable symptom, CHECK the MS-CAN

wiring between the SJB and the module in question for an
intermittent fault.
AE4 CHECK FOR CORRECT SJB
OPERATION
Yes
• Disconnect all the SJB INSTALL a new SJB . REFER to Section 419-10 . CLEAR all
connectors. continuous DTCs. TEST the system for normal operation.
• Check for:
♦ corrosion No
♦ damaged pins The system is operating correctly at this time. The concern may
♦ pushed-out pins have been caused by a loose or corroded connector. CLEAR all
• Connect all the SJB connectors continuous DTCs. REPEAT the self-test for the module(s) that
and make sure they seat set DTC U0140 or DTC U0140:00.
correctly.
PINPOINT TEST AE: DTC U0140 OR DTC U0140:00 5838

Pinpoint Test AF: DTC U0151:00
Normal Operation
The Accessory Protocol Interface Module (APIM) receives the emergency call notification message from the
Restraints Control Module (RCM) via the High Speed Controller Area Network (HS-CAN). This message
indicates to the APIM the status of the emergency call system.
As other modules outside of the audio system also receive this message, all modules receiving it should
exhibit a symptom if the message is missing.
• DTC U0151:00 (Lost Communication With Restraints Control Module: No Sub Type Information)
â set by the APIM when it is missing the emergency call notification message from the RCM over
the HS-CAN for greater than 5 seconds with the ignition in the RUN position.

• Restraints system concern
PINPOINT TEST AF: DTC U0151:00

AF1 CHECK FOR LOST COMMUNICATION
DTCs
Yes
• Clear continuous DTCs from all modules.
• Ignition ON. The system is operating correctly at this time. The
• Wait at least 10 seconds. DTC may have been set due to an intermittent fault
• Retrieve all continuous DTCs from all in the network wiring.
modules.
• Is DTC U0151 or DTC U0151:00 set in
any modules?
AF2 CHECK FOR BATTERY VOLTAGE
OUT-OF-RANGE DTCs
Yes
• Carry out the self-test for the following For the APIM , REFER to DTC Charts in this
modules: section.
♦ APIM
♦ PCM For all other modules, REFER to the master list in
♦ RCM Section 419-10 .
♦ Instrument Panel Cluster (IPC)
• Is DTC B1317, B1318, U3003:16, or No
U3003:17 recorded in any module? GO to AF3 .
AF3 CHECK FOR DTC U0151 OR DTC
U0151:00 SET IN MULTIPLE MODULES
Yes
• Review the recorded results from the GO to AF4 .
self-test.

• Is DTC U0151 or DTC U0151:00 set in No

more than one module? If there is an observable audio system symptom,
GO to Symptom Chart - General Audio System to
diagnose the observed symptom.
If there is an observable restraints system

symptom, REFER to Section 501-20B to diagnose
the symptom.
If there is no observable symptom, CHECK the

wiring between the APIM and the RCM for an
intermittent fault.
AF4 CHECK FOR CORRECT RCM
OPERATION
Yes
• Disconnect all the RCM connectors. INSTALL a new RCM . REFER to Section
• Check for: 501-20B . CLEAR all continuous DTCs. TEST the
♦ damaged pins
• Connect all the RCM connectors and make The system is operating correctly at this time. The
sure they seat correctly. concern may have been caused by a loose or
• Is the concern still present? corroded connector. CLEAR all continuous DTCs.
Pinpoint Test AG: DTC U0155 Or DTC U0155:00
Normal Operation
Several audio system modules receive network messages from the Instrument Panel Cluster (IPC) via the
Medium Speed Controller Area Network (MS-CAN). The following information is included in the messages:
• English/metric units
• Vehicle Identification Number (VIN)
• Transmission gear selected
• Vehicle speed
• DTC U0155 (Lost Communication With Instrument Panel Cluster ( IC )) â set by the
non-navigation (Fusion) Audio Front Control Module (ACM) or the Front Display Interface Module
(FDIM) when network messages are missing from the IPC for greater than 5 seconds with the ignition
in RUN.
• DTC U0155:00 (Lost Communication With Instrument Panel Cluster ( IPC ) Control Module: No Sub
Type Information) â set by the non-navigation (MKZ) or navigation (all) ACM , the audio Digital
Signal Processing (DSP) module, the Global Positioning System Module (GPSM), or the Accessory
Protocol Interface Module (APIM) when network messages are missing from the IPC for greater than
5 seconds with the ignition in RUN.
PINPOINT TEST AF: DTC U0151:00 5840

• IPC
PINPOINT TEST AG: DTC U0155 OR DTC U0155:00

AG1 CHECK FOR LOST
COMMUNICATION DTCs
Yes
modules. No
• Ignition OFF. The system is operating correctly at this time. The DTC
• Ignition ON. may have been set due to an intermittent fault in the
• Wait at least 10 seconds. network wiring.
• Retrieve all continuous DTCs from all
modules.
• Is DTC U0155 or DTC U0155:00 set
in any audio system module?
AG2 CHECK FOR BATTERY
Yes
• Carry out the self-test for the For an audio system module, REFER to DTC Charts in
following modules: this section.
♦ ACM
♦ Audio DSP module (if For the IPC , REFER to Section 413-01 .
equipped)
♦ APIM (if equipped) No
♦ FDIM GO to AG3 .
♦ GPSM
♦ IPC
• Is DTC B1317, B1318, U3003:16, or
U3003:17 recorded in any module?
AG3 CHECK FOR DTC U0155 OR DTC
Yes
• Review the recorded results from the GO to AG4 .
self-test.
• Is DTC U0155 or DTC U0155:00 set No
in more than one audio system If there is an observable symptom, GO to Symptom Chart
module? - General Audio System to diagnose the observed
symptom.

wiring between the SJB and the module in question for an
intermittent fault.
AG4 CHECK FOR CORRECT IPC
OPERATION
Yes

• Disconnect the IPC connector. INSTALL a new IPC . REFER to Section 413-01 .
• Check for: CLEAR all continuous DTCs. TEST the system for
♦ damaged pins
• Connect the IPC connector and make The system is operating correctly at this time. The
sure it seats correctly. concern may have been caused by a loose or corroded
• Is the concern still present? connector. CLEAR all continuous DTCs. REPEAT the
self-test for the module(s) that set DTC U0155 or DTC
U0155:00.
Pinpoint Test AH: DTC U0164 Or DTC U0164:00
Normal Operation
Some audio system modules receive network messages from the HVAC module via the Medium Speed
• HVAC indication status

• Outside temperature
• DTC U0164 (Lost Communication With HVAC Control Module ( EATC )) â set by the
non-navigation (Fusion) Front Controls Interface Module (FCIM) or the Front Display Interface
Module (FDIM) when network messages are missing from the HVAC module for greater than 5
• DTC U0164:00 (Lost Communication With HVAC Control Module: No Sub Type Information) â
set by the navigation Audio Front Control Module (ACM) when network messages are missing from
the HVAC module for greater than 5 seconds with the ignition in RUN.

• HVAC module
PINPOINT TEST AH: DTC U0164 OR DTC U0164:00

AH1 CHECK FOR LOST
COMMUNICATION DTCs
Yes
modules. No
PINPOINT TEST AG: DTC U0155 OR DTC U0155:00 5842

modules.
AH2 CHECK FOR BATTERY
Yes
• Carry out the self-test for the For an audio system module, REFER to DTC Charts in
following modules: this section.
♦ ACM
♦ FCIM For the HVAC module, REFER to Section 412-00A or
♦ FDIM Section 412-00B .
♦ HVAC module
• Is DTC B1317, B1318, U3003:16, or No
U3003:17 recorded in any module? GO to AH3 .
AH3 CHECK FOR DTC U0164 OR DTC
Yes
• Review the recorded results from the GO to AH4 .
self-test.
in more than one audio system If there is an observable symptom, GO to Symptom Chart
module? - General Audio System to diagnose the observed
symptom.

wiring between the HVAC module and the module in
question for an intermittent fault.
AH4 CHECK FOR CORRECT HVAC
MODULE OPERATION
Yes
• Disconnect all the HVAC module INSTALL a new HVAC module. REFER to Section
connectors. 412-01 . CLEAR all continuous DTCs. TEST the system
♦ corrosion
♦ damaged pins No
• Connect all the HVAC module concern may have been caused by a loose or corroded
connectors and make sure they seat connector. CLEAR all continuous DTCs. REPEAT the
correctly. self-test for the module(s) that set DTC U0164 or DTC
• Is the concern still present? U0164:00.
Pinpoint Test AI: DTC U016A:00
Normal Operation
• DTC U016A:00 (Lost Communication With Global Positioning System Module: No Sub Type
Information) â set by the Accessory Protocol Interface Module (APIM) when it is missing network
messages from the Global Positioning System Module (GPSM) over the Medium Speed Controller
Area Network (MS-CAN) for greater than 5 seconds with the ignition in the RUN position.
PINPOINT TEST AH: DTC U0164 OR DTC U0164:00 5843


• GPSM
• APIM
PINPOINT TEST AI: DTC U016A:00

AI1 CHECK THE APIM DTCs
Yes
NOTE: If new modules were installed prior to GO to AI2 .
the DTC being set, the module configuration
may be incorrectly set during Programmable No
Module Installation (PMI) or the PMI may not The system is operating correctly at this time.
have been carried out. The DTC may have been set due to an
intermittent fault in the network wiring.
• Clear the APIM DTCs.
• Ignition OFF.
• Ignition ON.
• Repeat the APIM self-test.
• Is DTC U016A:00 still present?
AI2 VERIFY THE CUSTOMER CONCERN
Yes
present. No
• Is an observable symptom present? The system is operating correctly at this time.
The DTC may have been set due to an
intermittent fault in the network wiring. CHECK
the MS-CAN wiring between the APIM and the
GPSM for an intermittent fault.
AI3 CHECK THE COMMUNICATION
NETWORK
Yes
• Carry out the network test using the scan tool.
• Does the GPSM pass the network test? No
AI4 CHECK FOR BATTERY VOLTAGE
OUT-OF-RANGE DTCs
Yes
• Carry out the self-test for the following REFER to DTC Charts in this section.
modules:
♦ APIM No
♦ GPSM INSTALL a new GPSM . REFER to Global
• Is DTC U3003:16 or DTC U3003:17 Positioning System Module (GPSM) â Fusion
recorded in either module? or Global Positioning System Module (GPSM)
â MKZ in this section. CLEAR the APIM
PINPOINT TEST AI: DTC U016A:00 5844

DTCs. REPEAT the APIM self-test.
If DTC U016A:00 is still present, INSTALL a

new APIM . REFER to Accessory Protocol
Interface Module (APIM) in this section. TEST
Pinpoint Test AJ: DTC U0184 Or DTC U0184:00
Normal Operation
Several audio system modules receive network messages from the Audio Front Control Module (ACM) via
the Medium Speed Controller Area Network (MS-CAN). These messages consist of various audio system
related information.
• DTC U0184 (Lost Communication With Radio ( ACM )) â set by theFront Controls Interface
Module (FCIM) (Fusion) or the Front Display Interface Module (FDIM) when network messages are
missing from the ACM for greater than 5 seconds with the ignition in RUN.
• DTC U0184:00 (Lost Communication With Radio: No Sub Type Information) â set by the audio
Digital Signal Processing (DSP) module, the Accessory Protocol Interface Module (APIM), the FCIM
(MKZ), and the Global Positioning System Module (GPSM) when network messages are missing
from the ACM for greater than 5 seconds with the ignition in RUN.

• ACM
PINPOINT TEST AJ: DTC U0184 OR DTC U0184:00

AJ1 CHECK FOR LOST
COMMUNICATION DTCs
Yes
• Ignition ON. GO to AJ2 .
modules. No
• Retrieve all continuous DTCs from
all modules.
• Is DTC U0184 or DTC U0184:00
set in any audio system module?

AJ2 CHECK FOR BATTERY

Yes
• Carry out the self-test for the REFER to DTC Charts in this section.
following modules:
♦ ACM No
♦ Audio DSP module (if GO to AJ3 .
equipped)
♦ APIM (if equipped)
♦ FCIM
♦ FDIM
♦ GPSM
• Is DTC B1317, B1318, U3003:16, or
AJ3 CHECK FOR DTC U0184 OR DTC
Yes
• Review the recorded results from the GO to AJ4 .
self-test.
• Is DTC U0184 or DTC U0184:00 No
set in more than one audio system If there is an observable symptom, REFER to the
module? appropriate Symptom Chart in this section.

wiring between the ACM and the module in question for
an intermittent fault.
AJ4 CHECK FOR CORRECT ACM
OPERATION
Yes
♦ corrosion (ACM) â MKZ in this section. CLEAR all continuous
♦ damaged pins DTCs. TEST the system for normal operation.
♦ pushed-out pins
• Is the concern still present? concern may have been caused by a loose or corroded
connector. CLEAR all continuous DTCs. REPEAT the
self-test for the module(s) that set DTC U0184 or DTC
U0184:00.
Pinpoint Test AK: DTC U0197 Or DTC U0197:00
Normal Operation
Several audio system modules receive network messages from the Accessory Protocol Interface Module
(APIM) via the Medium Speed Controller Area Network (MS-CAN). These messages consist of various audio
system related information.
PINPOINT TEST AJ: DTC U0184 OR DTC U0184:00 5846

• DTC U0197 (Lost Communication With Telephone Control Module) â set by the non-navigation
(Fusion) Audio Front Control Module (ACM) or the Front Display Interface Module (FDIM) when
network messages are missing from the APIM for greater than 5 seconds with the ignition in RUN.
• DTC U0197:00 (Lost Communication With Radio: No Sub Type Information) â set by the
non-navigation (MKZ) ACM , the navigation (all) ACM , the audio Digital Signal Processing (DSP)
module, or the Global Positioning System Module (GPSM) when network messages are missing from
the APIM for greater than 5 seconds with the ignition in RUN.

• APIM
PINPOINT TEST AK: DTC U0197 OR DTC U0197:00

AK1 CHECK FOR LOST
COMMUNICATION DTCs
Yes
• Ignition ON. GO to AK2 .
modules. No
modules.
AK2 CHECK FOR BATTERY
Yes
• Carry out the self-test for the REFER to DTC Charts in this section.
following modules:
♦ ACM No
♦ Audio DSP module (if GO to AK3 .
equipped)
♦ APIM (if equipped)
♦ FDIM
♦ GPSM
• Is DTC B1317, B1318, U3003:16, or
AK3 CHECK FOR DTC U0197 OR DTC
Yes
• Review the recorded results from the GO to AK4 .
self-test.


in more than one audio system If there is an observable symptom, REFER to the
module? appropriate Symptom Chart in this section.

wiring between the APIM and the module in question for
an intermittent fault.
AK4 CHECK FOR CORRECT APIM
OPERATION
Yes
• Disconnect the APIM connector. INSTALL a new APIM . REFER to Accessory Protocol
• Check for: Interface Module (APIM) in this section. CLEAR all
♦ corrosion continuous DTCs. TEST the system for normal operation.
♦ damaged pins
• Connect the APIM connector and The system is operating correctly at this time. The
make sure it seats correctly. concern may have been caused by a loose or corroded
• Wait 2 minutes for the APIM to connector. CLEAR all continuous DTCs. REPEAT the
re-initialize. self-test for the module(s) that set DTC U0197 or DTC
• Is the concern still present? U0197:00.
Pinpoint Test AL: DTC U0238 Or DTC U0238:00
Normal Operation
• DTC U0238 (Lost Communication With Digital Audio Control Module "D" ( DSP )) â set by the
non-navigation Audio Front Control Module (ACM) (Fusion) or the Front Display Interface Module
(FDIM) when network messages are missing from the audio Digital Signal Processing (DSP) module
over the Medium Speed Controller Area Network (MS-CAN) for greater than 5 seconds with the
ignition in the RUN position.
• DTC U0238:00 (Lost Communication With Digital Audio Control Module "D": No Sub Type
Information) â set by the non-navigation ACM (MKZ) or the navigation ACM when network
messages are missing from the audio DSP module over the MS-CAN for greater than 5 seconds with
the ignition in the RUN position.

• ACM
• FDIM
• APIM
PINPOINT TEST AL: DTC U0238 OR DTC U0238:00
NOTE: Only the non-navigation FDIM can set DTC U0238. Disregard the pinpoint test steps for the FDIM if
the concern is on a vehicle with navigation.

AL1 CHECK THE ACM AND FDIM DTCs
Yes
GO to AL2 .
PINPOINT TEST AK: DTC U0197 OR DTC U0197:00 5848

NOTE: If new modules were installed prior to the

DTC being set, the module configuration may be No
incorrectly set during Programmable Module The system is operating correctly at this
Installation (PMI) or the PMI may not have been time. The DTC may have been set due to an
carried out. intermittent fault in the network wiring.
• Clear the APIM and FDIM DTCs.

• Ignition OFF.
• Ignition ON.
• Repeat the APIM and FDIM self-tests.
• Is DTC U0238 or DTC U0238:00 still present?
AL2 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to AL3 .
time. The DTC may have been set due to an
CHECK the MS-CAN wiring between the
audio DSP module and the module in
question for an intermittent fault.
AL3 CHECK THE COMMUNICATION NETWORK
Yes
• Ignition ON. GO to AL4 .
• Does the audio DSP module pass the network No
test? REFER to Section 418-00 .
AL4 CHECK FOR BATTERY VOLTAGE
OUT-OF-RANGE DTCs
Yes
• Carry out the self-test for the following modules: REFER to DTC Charts in this section.
♦ ACM
♦ Audio DSP module No
♦ FDIM INSTALL a new audio DSP module.
• Is DTC B1316, B1317, U3003:16 or U3003:17 REFER to Audio Digital Signal Processing
recorded in any module? (DSP) Module in this section. CLEAR the
ACM and FDIM DTCs. REPEAT the ACM
and FDIM self-tests.
If DTC U0238:00 is still present in the

ACM , INSTALL a new ACM . REFER to
Audio Control Module (ACM) â Fusion
or Audio Control Module (ACM) â MKZ
in this section. TEST the system for normal
operation.

FDIM , INSTALL a new FDIM . REFER to
Front Display Interface Module (FDIM)
â Fusion or Front Display Interface
Module (FDIM) â MKZ in this section.
PINPOINT TEST AL: DTC U0238 OR DTC U0238:00 5849

Pinpoint Test AM: DTC U0255 Or DTC U0256:00
Normal Operation
• DTC U0255 (Lost Communication With Front Controls Interface Module) â set by the
non-navigation Audio Front Control Module (ACM) (Fusion) when network messages are missing
from the Front Controls Interface Module (FCIM) over the Medium Speed Controller Area Network
(MS-CAN) for greater than 5 seconds with the ignition in the RUN position.
• DTC U0256:00 (Lost Communication With Front Controls Interface Module: No Sub Type
Information) â set by the non-navigation ACM (MKZ), the navigation ACM (all), or the Accessory
Protocol Interface Module (APIM) when network messages are missing from the FCIM over the
MS-CAN for greater than 5 seconds with the ignition in the RUN position.

• ACM
• FCIM
• APIM
PINPOINT TEST AM: DTC U0255 OR DTC U0256:00
NOTE: Disregard the pinpoint test steps for the APIM if the concern is on a vehicle without the SYNCÂ®
system.

AM1 CHECK THE ACM AND APIM DTCs
Yes
NOTE: If new modules were installed GO to AM2 .
prior to the DTC being set, the module
configuration may be incorrectly set No
during Programmable Module The system is operating correctly at this time. The
Installation (PMI) or the PMI may not DTC may have been set due to an intermittent fault in
have been carried out. the network wiring.
• Clear the ACM and APIM DTCs.

• Ignition OFF.
• Ignition ON.
• Repeat the ACM and APIM self-tests.
• Is DTC U0255 or DTC U0256:00 still
present?
AM2 VERIFY THE CUSTOMER
CONCERN
Yes
• Ignition ON. GO to AM3 .
symptom present. No
• Is an observable symptom present? The system is operating correctly at this time. The
PINPOINT TEST AM: DTC U0255 OR DTC U0256:00 5850

DTC may have been set due to an intermittent fault in

the network wiring. CHECK the MS-CAN wiring
between the FCIM and the module in question for an
intermittent fault.
AM3 CHECK THE COMMUNICATION
NETWORK
Yes
• Ignition ON. GO to AM4 .
• Carry out the network test using the scan
tool. No
• Does the FCIM pass the network test? REFER to Section 418-00 .
AM4 CHECK FOR BATTERY VOLTAGE
OUT-OF-RANGE DTCs
Yes
• Carry out the self-test for the following REFER to DTC Charts in this section.
modules:
♦ ACM No
♦ APIM INSTALL a new FCIM . REFER to Front Controls
♦ FCIM Interface Module (FCIM) â Fusion or Front
• Is DTC B1316, B1317, U3003:16 or Controls Interface Module (FCIM) â MKZ in this
U3003:17 recorded in any module? section. CLEAR the ACM and APIM DTCs.
REPEAT the ACM and APIM self-tests.
If DTC U0255 (Fusion without navigation) or DTC

U0256:00 (all MKZ or Fusion with navigation) is still
present in the ACM , INSTALL a new ACM . REFER
to Audio Control Module (ACM) â Fusion or
Audio Control Module (ACM) â MKZ in this
If DTC U0256:00 is still present in the APIM ,

INSTALL a new APIM . REFER to Accessory
Protocol Interface Module (APIM) in this section.
Pinpoint Test AN: DTC U0256 Or DTC U0255:00
Normal Operation
• DTC U0256 (Lost Communication With Front Display Interface Module) â set by the
non-navigation Audio Front Control Module (ACM) (Fusion) when network messages are missing
from the Front Display Interface Module (FDIM) over the Medium Speed Controller Area Network
(MS-CAN) for greater than 5 seconds with the ignition in the RUN position.
• DTC U0255:00 (Lost Communication With Front Display Interface Module: No Sub Type
Information) â set by the non-navigation ACM (MKZ) or the Accessory Protocol Interface Module
(APIM) when network messages are missing from the FDIM over the MS-CAN for greater than 5
seconds with the ignition in the RUN position.

• ACM
• FDIM
PINPOINT TEST AM: DTC U0255 OR DTC U0256:00 5851

• APIM
PINPOINT TEST AN: DTC U0256 OR DTC U0255:00
NOTE: Disregard the pinpoint test steps for the APIM if the concern is on a vehicle without the SYNCÂ®
system.

AN1 CHECK THE ACM AND FDIM DTCs
Yes
NOTE: If new modules were installed prior to the GO to AN2 .
DTC being set, the module configuration may be
incorrectly set during Programmable Module No
Installation (PMI) or the PMI may not have been The system is operating correctly at this
carried out. time. The DTC may have been set due to an
• Clear the ACM and APIM DTCs.
• Ignition OFF.
• Ignition ON.
• Repeat the ACM and APIM self-tests.
• Is DTC U0256 or DTC U0255:00 still present?
AN2 VERIFY THE CUSTOMER CONCERN
Yes
• Ignition ON. GO to AN3 .
present. No
• Is an observable symptom present? The system is operating correctly at this
time. The DTC may have been set due to an
CHECK the MS-CAN wiring between the
FDIM and the module in question for an
intermittent fault.
AN3 CHECK THE COMMUNICATION
NETWORK
Yes
• Ignition ON. GO to AN4 .
• Does the FDIM pass the network test? No
AN4 CHECK FOR BATTERY VOLTAGE
OUT-OF-RANGE DTCs
Yes
• Carry out the self-test for the following modules: REFER to DTC Charts in this section.
♦ ACM
♦ APIM No
♦ FDIM INSTALL a new FDIM . REFER to Front
• Is DTC B1316, B1317, U3003:16 or U3003:17 Display Interface Module (FDIM) â
recorded in any module? Fusion or Front Display Interface Module
(FDIM) â MKZ in this section. CLEAR
PINPOINT TEST AN: DTC U0256 OR DTC U0255:00 5852

the ACM and APIM DTCs. REPEAT the

ACM and APIM self-tests.
If DTC U0256 (Fusion) or DTC U0255:00

(MKZ) is still present in the ACM ,
INSTALL a new ACM . REFER to Audio
Control Module (ACM) â Fusion or
Audio Control Module (ACM) â MKZ in
this section. TEST the system for normal
operation.

APIM , INSTALL a new APIM . REFER to
Accessory Protocol Interface Module
(APIM) in this section. TEST the system for
normal operation.
Pinpoint Test AO: DTC B1318 Or DTC U3003:16 (Audio Front Control Module (ACM))
Normal Operation
• DTC B1318 (Battery Voltage Low) â set by the non-navigation (Fusion) Audio Front Control
Module (ACM) as a continuous or on-demand DTC when the supply voltage falls below 10 volts for
at least 10 seconds during normal operation.
• DTC U3003:16 (Battery Voltage: Circuit Voltage Below Threshold) â set by the non-navigation
(MKZ) or navigation (all) ACM as a continuous or on-demand DTC when the supply voltage falls
below 10 volts for at least 10 seconds during normal operation, or for greater than 250 milliseconds
during the self-test.

• ACM
PINPOINT TEST AO: DTC B1318 Or DTC U3003:16 ( ACM )
Section 414-01 .

AO1 RECHECK THE ACM DTCs
Yes
• Clear the ACM DTCs. GO to AO2 .
• Ignition OFF.
• Ignition ON. No
PINPOINT TEST AO: DTC B1318 Or DTC U3003:16 ( ACM ) 5853

• Wait 10 seconds. The system is operating correctly at this time. The

• Repeat the ACM self-test. DTC may have set due to a previous low battery
• Is DTC B1318 or DTC U3003:16 still voltage condition.
present?
AO2 CHECK FOR CHARGING SYSTEM
DTCs IN THE PCM
Yes
• Retrieve the continuous memory DTCs REFER to Section 414-00 .
from all modules.
• Is DTC P0620, P0622, P0625, P0626, No
or P065B set in the PCM? GO to AO3 .
AO3 CHECK THE BATTERY
CONDITION AND STATE OF CHARGE
Yes
• Check the battery condition and verify GO to AO4 .
that the battery is fully charged. Refer to
Section 414-01 . No
• Is the battery OK and fully charged? REFER to Section 414-01 .
AO4 CHECK THE ACM VOLTAGE
SUPPLY
Yes
• Measure and record the voltage at the
battery. No
• Disconnect: ACM C240a . REPAIR the circuit for high resistance. CLEAR the
• Ignition ON. DTCs. REPEAT the self-test.
• Measure the voltage between the ACM
C240a-1, circuit SBP39 (WH/RD),
• Is the voltage within 0.2 volt of the

recorded battery voltage?
AO5 CHECK THE ACM GROUND
Yes
ACM C240a-13, circuit GD114 REPAIR the circuit for high resistance. CLEAR the
(BK/BU), harness side and ground. DTCs. REPEAT the self-test.
PINPOINT TEST AO: DTC B1318 Or DTC U3003:16 ( ACM ) 5854


AO6 CHECK FOR CORRECT ACM
OPERATION
Yes
♦ corrosion (ACM) â MKZ in this section. TEST the system for
♦ pushed-out pins
connector.
Pinpoint Test AP: DTC U3003:17 (Audio Front Control Module (ACM))
Normal Operation
• DTC U3003:17 (Battery Voltage: Circuit Voltage Above Threshold) â set by the Audio Front
Control Module (ACM) when the supply voltage is greater than 15.8 volts for more than 250
milliseconds during normal operation or the self-test.

• ACM
PINPOINT TEST AP: DTC U3003:17 ( ACM )
starting events.

AP1 CHECK FOR HIGH VOLTAGE
DTCs SET IN OTHER MODULES
Yes
• Ignition ON. REFER to Section 414-00 to diagnose an overcharging
• Retrieve all continuous DTCs condition.
from all modules.
• Is DTC B1317, B1676, or B0563 No
(PCM), or U3003:17 set in GO to AP2 .
more than one module?
AP2 CHECK THE BATTERY
VOLTAGE
PINPOINT TEST AP: DTC U3003:17 ( ACM ) 5855

• Turn off all interior/exterior Yes

lights and accessories. REFER to Section 414-00 to diagnose an overcharging
• Start and run the engine at condition.
approximately 2,000 rpm for 3
minutes while monitoring the No
battery voltage. GO to AP3 .
• Does the battery voltage rise to
15.5 volts or higher?
AP3 RECHECK FOR DTC U3003:17
Yes
• Turn the engine off. INSTALL a new ACM . REFER to Audio Control Module
• Ignition ON. (ACM) â Fusion or Audio Control Module (ACM) â
• Clear the ACM DTCs. MKZ in this section. TEST this system for normal operation.
• Repeat the ACM self-test.
• Is DTC U3003:17 still present? No
The system is operating normally at this time. The DTC may
have been set previously during battery charging or while
jump starting the vehicle.
Pinpoint Test AQ: DTC U3003:16 (Accessory Protocol Interface Module (APIM))
Normal Operation
• DTC U3003:16 (Battery Voltage: Circuit Voltage Below Threshold) â set by the Accessory
Protocol Interface Module (APIM) when the supply voltage falls below 10 volts for at least 10
seconds during normal operation.

• APIM
PINPOINT TEST AQ: DTC U3003:16 ( APIM )
Section 414-01 .

AQ1 RECHECK THE APIM DTCs
Yes
• Clear the APIM DTCs. GO to AQ2 .
• Ignition OFF.
• Ignition ON. No
• Wait at least 15 seconds. The system is operating correctly at
PINPOINT TEST AQ: DTC U3003:16 ( APIM ) 5856

• Repeat the APIM self-test. this time. The DTC may have set due
• Is DTC U3003:16 still present? to a previous low battery voltage
condition.
AQ2 CHECK FOR CHARGING SYSTEM DTCs IN THE
PCM
Yes
• Retrieve the continuous memory DTCs from all REFER to Section 414-00 .
modules.
• Is DTC P0620, P0622, P0625, or P065B set in the No
PCM? GO to AQ3 .
AQ3 CHECK THE BATTERY CONDITION AND STATE
OF CHARGE
Yes
• Check the battery condition and verify that the battery is GO to AQ4 .
fully charged. Refer to Section 414-01 .
AQ4 CHECK THE APIM VOLTAGE SUPPLY
Yes
• Measure and record the voltage at the battery.
• Disconnect: APIM C3338 . No
• Ignition ON. REPAIR the circuit for high resistance.
• Measure the voltage between the APIM C3338-1, circuit CLEAR the DTCs. REPEAT the
SBB13 (GY/RD), harness side and ground. self-test.
• Is the voltage within 0.2 volt of the recorded battery

voltage?
AQ5 CHECK THE APIM GROUND CIRCUITS FOR
CONTINUITY
Yes
• Measure the resistance between the APIM C3338-37, No
circuit GD148 (BK/YE), harness side and ground; and REPAIR the circuit in question for
between the APIM C3338-38, circuit GD148 (BK/YE), high resistance. CLEAR the DTCs.
harness side and ground. REPEAT the self-test.
PINPOINT TEST AQ: DTC U3003:16 ( APIM ) 5857


AQ6 CHECK FOR CORRECT APIM OPERATION
Yes
• Disconnect the APIM connector. INSTALL a new APIM . REFER to
• Check for: Accessory Protocol Interface Module
♦ corrosion (APIM) in this section. TEST the
♦ damaged pins system for normal operation.
♦ pushed-out pins
• Wait 2 minutes for the APIM to re-initialize. this time. The concern may have been
connector.
Pinpoint Test AR: DTC U3003:17 (Accessory Protocol Interface Module (APIM))
Normal Operation
• DTC U3003:17 (Battery Voltage: Circuit Voltage Above Threshold) â set by the Accessory
Protocol Interface Module (APIM) when the supply voltage is greater than 15.8 volts for more than
250 milliseconds during normal operation.

• APIM
PINPOINT TEST AR: DTC U3003:17 ( APIM )
starting events.

AR1 CHECK FOR HIGH VOLTAGE
Yes
• Retrieve the continuous DTCs from condition.
all modules.
• Is DTC B1317, B1676, B0563 No
(PCM), or U3003:17 set in more GO to AR2 .
than one module?
AR2 CHECK THE BATTERY
VOLTAGE
PINPOINT TEST AR: DTC U3003:17 ( APIM ) 5858

• Turn off all interior/exterior lights Yes

and accessories. REFER to Section 414-00 to diagnose an overcharging
• Start and run the engine at condition.
approximately 2,000 rpm for 3
minutes while monitoring the battery No
voltage. GO to AR3 .
• Does the battery voltage rise to 15.5
volts or higher?
AR3 RECHECK FOR DTC B1317
Yes
• Ignition OFF. INSTALL a new APIM . REFER to Accessory Protocol
• Ignition ON. Interface Module (APIM) in this section. TEST this
• Clear the APIM DTCs. system for normal operation.
• Repeat the APIM self-test.
• Is DTC U3003:17 present? No
The system is operating normally at this time. The DTC
may have been set previously during battery charging or
while jump starting the vehicle.
Pinpoint Test AS: DTC U3003:16 (Audio Digital Signal Processing (DSP) Module)
Normal Operation
• DTC U3003:16 (Battery Voltage: Circuit Voltage Below Threshold) â set by the audio Digital
Signal Processing (DSP) module when the supply voltage falls below 10 volts for at least 10 seconds
during normal operation, or for greater than 250 milliseconds during the self-test.

PINPOINT TEST AS: DTC U3003:16 (AUDIO DSP MODULE)
Section 414-01 .

AS1 RECHECK THE AUDIO DSP MODULE DTCs
Yes
• Clear the audio DSP module DTCs. GO to AS2 .
• Ignition OFF.
• Ignition ON. No
• Wait at least 15 seconds. The system is operating correctly at
PINPOINT TEST AS: DTC U3003:16 (AUDIO DSP MODULE) 5859

• Repeat the audio DSP module self-test. this time. The DTC may have set
• Is DTC U3003:16 still present? due to a previous low battery
voltage condition.
AS2 CHECK FOR CHARGING SYSTEM DTCs IN THE
PCM
Yes
• Retrieve the continuous memory DTCs from all modules. REFER to Section 414-00 .
• Is DTC P0620, P0622, P0625, or P065B set in the PCM?
No
GO to AS3 .
AS3 CHECK THE BATTERY CONDITION AND STATE OF
CHARGE
Yes
• Check the battery condition and verify that the battery is GO to AS4 .
fully charged. Refer to Section 414-01 .
AS4 CHECK THE AUDIO DSP MODULE VOLTAGE
SUPPLY
Yes
• Ignition OFF. GO to AS5 .
• Measure and record the voltage at the battery.
• Disconnect: Audio DSP Module C4240a (SonyÂ® Sound) No
or C4235a (THXÂ® Sound) . REPAIR the circuit in question for
• Ignition ON. high resistance. CLEAR the DTC.
• For vehicles with SonyÂ® sound, measure the voltage REPEAT the self-test.
between the audio DSP module C4240a-5, circuit SBP19
(BU/RD), harness side and ground; and between the audio
DSP module C4240a-6, circuit SBP19 (BU/RD), harness
side and ground.
• For vehicles with THXÂ® sound, measure the voltage

between the audio DSP module, harness side and ground as
follows:

C4235a-9 Ground
SBB20 (GN/RD)
C4235a-10 Ground

SBB20 (GN/RD)
C4235a-11 Ground
SBB21 (GY/RD)
C4235a-12 Ground
SBB21 (GY/RD)
• Are the voltages within 0.2 volt of the recorded battery

voltage?
AS5 CHECK THE AUDIO DSP MODULE GROUND
Yes
• Ignition OFF. GO to AS6 .
• For vehicles with SonyÂ® audio, measure the resistance No
between the audio DSP module C4240a-13, circuit GD148 REPAIR the circuit in question for
(BK/YE), harness side and ground; and between the audio high resistance. TEST the system
DSP module C4240a-14, circuit GD148 (BK/YE), harness for normal operation.
side and ground.
• For vehicles with THXÂ® audio, measure the resistance

between the audio DSP module, harness side and ground as
follows:

C4235a-22 GD148 (BK/YE)
C4235a-23 GD148 (BK/YE)
C4235a-24 GD148 (BK/YE)


AS6 CHECK FOR CORRECT AUDIO DSP MODULE
OPERATION
Yes
• Disconnect all the audio DSP module connectors. INSTALL a new audio DSP
• Check for: module. REFER to Audio Digital
♦ corrosion Signal Processing (DSP) Module in
♦ damaged pins this section. TEST the system for
• Connect all the audio DSP module connectors and make
sure they seat correctly. No
• Is the concern still present? The system is operating correctly at
this time. The concern may have
connector.
Pinpoint Test AT: DTC U3003:17 (Audio Digital Signal Processing (DSP) Module)
Normal Operation
• DTC U3003:17 (Battery Voltage: Circuit Voltage Above Threshold) â set by the audio Digital
Signal Processing (DSP) module when the supply voltage is greater than 15.8 volts for more than 250

PINPOINT TEST AT: DTC U3003:17 (AUDIO DSP MODULE)
starting events.

AT1 CHECK FOR HIGH VOLTAGE
Yes
• Retrieve all continuous DTCs from condition.
all modules.
• Is DTC B1317, B1676, or B0563 No
(PCM), or U3003:17 set in more GO to AT2 .
than one module?
PINPOINT TEST AT: DTC U3003:17 (AUDIO DSP MODULE) 5862

AT2 CHECK THE BATTERY

VOLTAGE
Yes
• Turn off all interior/exterior lights REFER to Section 414-00 to diagnose an overcharging
and accessories. condition.
• Start and run the engine at
approximately 2,000 rpm for 3 No
minutes while monitoring the battery GO to AT3 .
voltage.
• Does the battery voltage rise to
15.5 volts or higher?
AT3 RECHECK FOR DTC U3003:17
Yes
• Turn the engine off. INSTALL a new audio DSP module. REFER to Audio
• Ignition ON. Digital Signal Processing (DSP) Module in this section.
• Clear the audio DSP module DTCs. TEST this system for normal operation.
• Repeat the audio DSP module
self-test. No
• Is DTC U3003:17 present? The system is operating normally at this time. The DTC
may have been set previously during battery charging or
Pinpoint Test AU: DTC B1318 Or DTC U3003:16 (Front Controls Interface Module (FCIM))
Normal Operation
• DTC B1318 (Battery Voltage Low) â set by the non-navigation (Fusion) Front Controls Interface
Module (FCIM) when the supply voltage falls below 10 volts for greater than 10 seconds during
normal operation or during the self-test.
• DTC U3003:16 (Battery Voltage: Circuit Voltage Below Threshold) â set by the non-navigation
(MKZ) or navigation (all) FCIM when the supply voltage falls below 10 volts for greater than 10
seconds during normal operation or for greater than 250 milliseconds during the self-test.

• FCIM
PINPOINT TEST AU: DTC B1318 OR DTC U3003:16 ( FCIM )
Section 414-01 .
PINPOINT TEST AU: DTC B1318 OR DTC U3003:16 ( FCIM ) 5863

AU1 RECHECK THE FCIM DTCs

Yes
• Clear the FCIM DTCs. GO to AU2 .
• Ignition OFF.
• Ignition ON. No
• Wait at least 15 seconds. The system is operating correctly at this time. The
• Repeat the FCIM self-test. DTC may have set due to a previous low battery
• Is DTC B1318 or DTC U3003:16 still voltage condition.
present?
AU2 CHECK FOR CHARGING SYSTEM
DTCs IN THE PCM
Yes
from all modules.
• Is DTC P0620, P0622, P0625, or P065B No
set in the PCM? GO to AU3 .
AU3 CHECK THE BATTERY CONDITION
AND STATE OF CHARGE
Yes
• Check the battery condition and verify GO to AU4 .
that the battery is fully charged. Refer to
Section 414-01 . No
AU4 CHECK THE FCIM VOLTAGE
SUPPLY
Yes
battery. No
• Disconnect: FCIM C2403 (Fusion REPAIR the circuit for high resistance. CLEAR the
Without Navigation), C2408 (Fusion DTC. REPEAT the self-test.
With Navigation), or C2402 (MKZ) .
• Ignition ON.
• Measure the voltage between the FCIM ,
Positive Negative
Vehicle Meter Meter
Equipment Lead Lead
Fusion without C2403-1 Ground
navigation
SBP14
(BN/RD)
Fusion with C2408-1 Ground
navigation
SBP14
(BN/RD)
MKZ C2402-5 Ground

SBP14
(BN/RD)

AU5 CHECK THE FCIM GROUND
Yes
FCIM , harness side and ground as REPAIR the circuit for high resistance. TEST the
follows: system for normal operation.
Positive Negative
Vehicle Meter Meter
Equipment Lead Lead
Fusion without C2403-2 Ground
navigation
GD116
(BK/VT)
Fusion with C2408-4 Ground
navigation
GD116
(BK/VT)
MKZ C2402-8 Ground
GD116
(BK/VT)


AU6 CHECK FOR CORRECT FCIM
OPERATION
Yes
• Disconnect the FCIM connector. INSTALL a new FCIM . REFER to Front Controls
• Check for: Interface Module (FCIM) â Fusion or Front
♦ corrosion Controls Interface Module (FCIM) â MKZ in this
♦ damaged pins section. TEST the system for normal operation.
♦ pushed-out pins
• Connect the FCIM connector and make No
sure it seats correctly. The system is operating correctly at this time. The
connector.
Pinpoint Test AV: DTC U3003:17 (Front Controls Interface Module (FCIM))
Normal Operation
• DTC U3003:17 (Battery Voltage: Circuit Voltage Above Threshold) â set by the Front Controls
Interface Module (FCIM) when the supply voltage is greater than 15.8 volts for more than 250

• FCIM
PINPOINT TEST AV: DTC U3003:17 ( FCIM )
starting events.

AV1 CHECK FOR HIGH
VOLTAGE DTCs SET IN OTHER
MODULES
Yes
PINPOINT TEST AV: DTC U3003:17 ( FCIM ) 5866


• Retrieve all continuous DTCs condition.
from all modules.
• Is DTC B1317, B1676, or No
B0563 (PCM), or U3003:17 GO to AV2 .
set in more than one module?
AV2 CHECK THE BATTERY
VOLTAGE
Yes
• Turn off all interior/exterior REFER to Section 414-00 to diagnose an overcharging
lights and accessories. condition.
minutes while monitoring the GO to AV3 .
battery voltage.
• Does the battery voltage rise
to 15.5 volts or higher?
AV3 RECHECK FOR DTC
U3003:17
Yes
• Turn the engine off. INSTALL a new FCIM . REFER to Front Controls Interface
• Ignition ON. Module (FCIM) â Fusion or Front Controls Interface Module
• Clear the FCIM DTCs. (FCIM) â MKZ in this section. TEST this system for normal
• Repeat the FCIM self-test. operation.
• Is DTC U3003:17 present?
No
have been set previously during battery charging or while jump
starting the vehicle.
Pinpoint Test AW: DTC B1318 (Front Display Interface Module (FDIM))
Normal Operation
• DTC B1318 (Battery Voltage Low) â set by the Front Display Interface Module (FDIM) when the
supply voltage falls below 10 volts for greater than 10 seconds during normal operation or during the
self-test.

• FDIM
PINPOINT TEST AW: DTC B1318 ( FDIM )
PINPOINT TEST AW: DTC B1318 ( FDIM ) 5867

Section 414-01 .

AW1 RECHECK THE FDIM DTCs
Yes
• Clear the FDIM DTCs. GO to AW2 .
• Ignition OFF.
• Ignition ON. No
• Wait at least 15 seconds. The system is operating correctly at this time. The DTC
• Repeat the FDIM self-test. may have set due to a previous low battery voltage
• Is DTC B1318 still present? condition.
AW2 CHECK FOR CHARGING
SYSTEM DTCs IN THE PCM
Yes
from all modules.
• Is DTC P0620, P0622, P0625, or No
P065B set in the PCM? GO to AW3 .
AW3 CHECK THE BATTERY
CONDITION AND STATE OF CHARGE
Yes
• Check the battery condition and verify GO to AW4 .
that the battery is fully charged. Refer
to Section 414-01 . No
AW4 CHECK THE FDIM VOLTAGE
SUPPLY
Yes
• Ignition OFF. GO to AW5 .
battery. No
• Disconnect: FDIM . REPAIR the circuit for high resistance. CLEAR the
• Ignition ON. DTC. REPEAT the self-test.
• Measure the voltage between the
FDIM C2407-12, circuit SBP14
(BN/RD), harness side and ground.

AW5 CHECK THE FDIM GROUND
PINPOINT TEST AW: DTC B1318 ( FDIM ) 5868


• Disconnect: Negative Battery Cable . GO to AW6 .
FDIM C2407-8, circuit GD116 No
(BK/VT), harness side and ground. REPAIR the circuit for high resistance. TEST the

AW6 CHECK FOR CORRECT FDIM
OPERATION
Yes
• Disconnect the FDIM connector. INSTALL a new FDIM . REFER to Front Display
• Check for: Interface Module (FDIM) â Fusion or Front Display
♦ corrosion Interface Module (FDIM) â MKZ in this section.
♦ pushed-out pins
• Connect the FDIM connector and No
make sure it seats correctly. The system is operating correctly at this time. The
connector.
Pinpoint Test AX: DTC U3003:16 Global Positioning System Module (GPSM))
Normal Operation
• DTC U3003:16 (Battery Voltage: Circuit Voltage Below Threshold) â set by the Global
Positioning System Module (GPSM) when the supply voltage falls below 10 volts for at least 10
seconds during normal operation, or for greater than 250 milliseconds during the self-test.

• GPSM
PINPOINT TEST AX: DTC U3003:16 ( GPSM )
PINPOINT TEST AX: DTC U3003:16 ( GPSM ) 5869

Section 414-01 .

AX1 RECHECK THE GPSM DTCs
Yes
• Clear the GPSM DTCs. GO to AX2 .
• Ignition OFF.
• Ignition ON. No
• Wait at least 15 seconds. The system is operating correctly at this time. The
• Repeat the GPSM self-test. DTC may have set due to a previous low battery
• Is DTC U3003:16 still present? voltage condition.
AX2 CHECK FOR CHARGING SYSTEM
DTCs IN THE PCM
Yes
• Retrieve the continuous memory DTCs from REFER to Section 414-00 .
all modules.
• Is DTC P0620, P0622, P0625, or P065B No
set in the PCM? GO to AX3 .
AX3 CHECK THE BATTERY CONDITION
AND STATE OF CHARGE
Yes
• Check the battery condition and verify that GO to AX4 .
the battery is fully charged. Refer to Section
414-01 . No
AX4 CHECK THE GPSM VOLTAGE SUPPLY
Yes
• Ignition OFF. GO to AX5 .
battery. No
• Disconnect: GPSM C2300 . REPAIR the circuit in question for high resistance.
• Ignition ON. CLEAR the DTC. REPEAT the self-test.
• Measure the voltage between the GPSM
C2300-1, circuit SBP14 (BN/RD), harness
side and ground.

AX5 CHECK THE GPSM GROUND
CIRCUITS
PINPOINT TEST AX: DTC U3003:16 ( GPSM ) 5870


• Disconnect: Negative Battery Cable . GO to AX6 .
• Measure the resistance between the GPSM
C2300-6, circuit GD116 (BK/VT), harness No
side and ground. REPAIR the circuit in question for high resistance.

AX6 CHECK FOR CORRECT GPSM
OPERATION
Yes
• Disconnect the GPSM connector. INSTALL a new GPSM . REFER to Global
• Check for: Positioning System Module (GPSM) â Fusion
♦ corrosion or Global Positioning System Module (GPSM)
♦ damaged pins â MKZ in this section. TEST the system for
• Connect the GPSM connector and make sure
it seats correctly. No
• Is the concern still present? The system is operating correctly at this time. The
concern may have been caused by a loose or
corroded connector.
Pinpoint Test AY: DTC U3003:17 (Global Positioning System Module (GPSM))
Normal Operation
• DTC U3003:17 (Battery Voltage: Circuit Voltage Above Threshold) â set by the Global
Positioning System Module (GPSM) when the supply voltage is greater than 15.8 volts for more than
250 milliseconds during normal operation or the self-test.

• GPSM
PINPOINT TEST AY: DTC U3003:17 ( GPSM )
starting events.

AY1 CHECK FOR HIGH
VOLTAGE DTCs SET IN OTHER
MODULES
PINPOINT TEST AY: DTC U3003:17 ( GPSM ) 5871


• Retrieve all continuous DTCs REFER to Section 414-00 to diagnose an overcharging
from all modules. condition.
• Is DTC B1317, B1676, or
B0563 (PCM), or U3003:17 No
set in more than one module? GO to AY2 .
AY2 CHECK THE BATTERY
VOLTAGE
Yes
• Turn off all interior/exterior REFER to Section 414-00 to diagnose an overcharging
lights and accessories. condition.
minutes while monitoring the GO to AY3 .
battery voltage.
• Does the battery voltage rise
to 15.5 volts or higher?
AY3 RECHECK FOR DTC
U3003:17
Yes
• Turn the engine off. INSTALL a new GPSM . REFER to Global Positioning System
• Ignition ON. Module (GPSM) â Fusion or Global Positioning System
• Clear the GPSM DTCs. Module (GPSM) â MKZ in this section. TEST this system for
• Repeat the GPSM self-test. normal operation.
• Is DTC U3003:17 present?
No
have been set previously during battery charging or while jump
starting the vehicle.
Pinpoint Test AZ: The Audio System Does Not Operate Correctly From The Front Display Interface
Module (FDIM) â MKZ Without Navigation
Normal Operation
When a button is pressed on the Front Display Interface Module (FDIM), a message is broadcast to the Audio
Front Control Module (ACM) via the Medium Speed Controller Area Network (MS-CAN). The ACM then
takes the appropriate action.
• DTC B2924 (Audio Button Stuck) â sets when the FDIM detects a button as active for greater than
120 seconds during normal operation, or for any duration during the self-test. When this occurs, the
FDIM disables that particular button until the fault is cleared, or until the next ignition cycle.

• FDIM

PINPOINT TEST AZ: THE AUDIO SYSTEM DOES NOT OPERATE CORRECTLY FROM THE FDIM â MKZ
WITHOUT NAVIGATION

AZ1 CHECK the FDIM DTCs
Yes
• Clear the FDIM DTCs. INSTALL a new FDIM . REFER to Front Display
• Carry out the FDIM self-test, making sure Interface Module (FDIM) â MKZ in this section.
no buttons are pressed while the self-test TEST the system for normal operation.
is running.
GO to AZ2 .
AZ2 OBSERVE THE FDIM DISPLAY
Yes
• Turn the audio system on and observe the GO to Pinpoint Test N .
FDIM screen.
• Is the FDIM display completely No
inoperative? GO to AZ3 .
AZ3 CHECK FOR CORRECT FDIM
OPERATION
Yes
• Ignition OFF. INSTALL a new FDIM . REFER to Front Display
• Disconnect the FDIM connector. Interface Module (FDIM) â MKZ in this section.
• Check for: TEST this system for normal operation.
♦ corrosion
♦ damaged pins No
• Connect the FDIM connector and make concern may have been caused by a loose or corroded
sure it seats correctly. connector.
Pinpoint Test BA: SYNCÂ® Traffic, Directions And Information Service Is Inoperative
Normal Operation
The SYNCÂ® traffic, directions and information service is a subscription-based service that includes precise
turn-by-turn directions, personalized real-time traffic updates with text alerts, business search, entertainment,
news, sports, stocks, travel and weather. The customer's mobile phone is used to access and download the
SYNCÂ® services. The Global Positioning System (GPS) antenna (integral to the Global Positioning System
Module (GPSM)) is used to detect the location and direction of the vehicle. For additional information on the
traffic, direction and information services subscription refer to the SyncMyRide website .
• Accessory Protocol Interface Module (APIM)

• GPSM
• Subscription expired
PINPOINT TEST AZ: THE AUDIO SYSTEM DOES NOT OPERATE CORRECTLY FROM THE 5873
FDIM â M
PINPOINT TEST BA: SYNCÂ® TRAFFIC, DIRECTIONS AND INFORMATION SERVICE IS INOPERATIVE

BA1 VERIFY THE CUSTOMER
SUBSCRIPTION AND PHONE
NUMBER
Yes
• NOTE: Prior to performing GO to BA2 .
this pinpoint test step, inquire
with the customer about No
SYNCÂ® traffic, directions If the subscription is not activated, INFORM the customer that in
and information service order for the SYNCÂ® traffic, directions and information to
registration. function the subscription needs to be activated on the SYNCÂ®
• Verify that the customer has website. REFER to the SyncMyRide website . If the phone
an active subscription and the number is incorrect, INFORM the customer that the correct
correct phone number that is phone number must be registered on the SYNCÂ® website.
registered on the SYNCÂ® REFER to the SyncMyRide website .
website. REFER to the
SyncMyRide website .
• Is the subscription activated
and the correct phone
number registered?
BA2 CHECK FOR APIM DTCs
Yes
• Ignition ON. REFER to the APIM DTC Chart in this section.
• Carry out the APIM self-test.
• Are any DTCs recorded in No
the APIM ? GO to BA3 .
BA3 CHECK FOR GPSM DTCs
Yes
• Carry out the GPSM self-test. REFER to the GPSM DTC Chart in this section.
• Are any DTCs recorded in
the GPSM ? No
INSTALL a new GPSM . For Fusion, REFER to Global
Positioning System Module (GPSM) â Fusion . For MKZ,
REFER to Global Positioning System Module (GPSM) â MKZ
.
Pinpoint Test BB: Poor Sound Quality Or Distorted Sound From One Or More Speakers (Not All
Speakers)
Diagnostic Overview
Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
Refer to Diagnostic Methods in Section 100-00 for information about these practices.
Normal Operation
The Audio Front Control Module (ACM) sends audio signals to the speakers in the form of AC voltage,
resulting in clear audio output.
Possible Sources
PINPOINT TEST BA: SYNCÂ® TRAFFIC, DIRECTIONS AND INFORMATION SERVICE IS INOPERATIVE
5874
• Wiring, terminals, or connectors
• Speaker(s)
• Loose trim panel fasteners
• Loose trim panels
• Loose speaker grille
• Loose harnesses
• Loose items in storage areas
• Loose harness fasteners
• Loose door and handle lock components
• Loose component fasteners
• Watershield bonding and placement
• Subwoofer enclosure
PINPOINT TEST BB: POOR SOUND QUALITY OR DISTORTED SOUND FROM ONE OR MORE SPEAKERS (NOT
ALL SPEAKERS)

BB1 ISOLATE THE ZONE
Yes
• Operate the audio system using digital media (CD, MP3, REPAIR or REPLACE the trim panel
etc.). as needed.
• Using the audio system fade and balance feature, adjust
the audio sound to each of the four zones (LF, RF, LR No
and RR) of the vehicle to isolate the poor sound quality. GO to BB2 .
• Locate and apply pressure to the trim panel(s) around
the poor sound quality area in question.
• Does applying pressure to a trim panel reduce or
eliminate the audible noise?
BB2 REMOVE AND INSPECT BEHIND/UNDERNEATH
THE SUSPECT TRIM PANEL(S)
Yes
• Remove the trim panel to access the suspect speaker. REPAIR or REPLACE any loose or
• Operate the audio system using digital media (CD, MP3, broken component or fastener as
etc.). needed.
• Validate where the poor sound quality area is located.
• Check: No
♦ Trim panel for loose components (e.g. speaker GO to BB3 .
grille) around the speaker area.
♦ Trim panel joining components for missing or
broken pieces.
♦ Lock and handle mechanical parts for correct
attachment.
♦ Wire harnesses for correct routing.
♦ Wire harness fasteners for correct attachment.
♦ Watershield for correct placement (speaker air
path not blocked).
♦ Watershield for correct bonding to sheet metal.
♦ Storage areas for loose items.
♦ All child safety belt anchors (if equipped).
♦ All safety belt retractors.
♦ All speaker bracket fasteners and other fasteners
are secured and tightened to specified torque.

• Was the source of the noise located?

BB3 CHECK THE SUSPECT SPEAKER FOR WATER
INTRUSION
Yes
• Inspect for watermarks. VERIFY the water shield is in the
• Check the: correct location, REPAIR or
♦ Cone. REPLACE any trim, door, or speaker
♦ Magnet. seal as required.
♦ Basket.
• Are any watermarks present on the speaker? DRY the speaker in question and
No
GO to BB4 .
BB4 ISOLATE SPEAKER TO VERIFY NOISE
Yes
• Remove the suspect speaker from its location and leave INSTALL a new speaker for the one in
the speaker connected to the harness. question.
• Hold the speaker away from any trim panel(s) and
ensure the speaker is isolated from contact. No
• Operate the audio system using digital media (CD, MP3, LOCATE the source of the noise and
etc.). REPAIR as needed.
• Is the noise still present in the suspect speaker?
PINPOINT TEST BB: POOR SOUND QUALITY OR DISTORTED SOUND FROM ONE OR MORE
5876SPEAKE
SECTION 415-00: Information and 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid
Entertainment Systems Workshop Manual
Audio Control Module (ACM) Self-Diagnostic Mode
Audio Systems Without Navigation
NOTE: If the Audio Front Control Module (ACM) is inoperable the ACM part number may be obtained from
a label affixed to the chassis.
1. Turn the ACM on.
2. Operate the audio system in radio tuner (AM/FM) mode.
3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins.
• The display indicates each speaker as it is tested.
4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after Step 3 by
turning the ACM off.
Before the speaker walk test is complete, carry out any of the following actions:
Preset
Button Diagnostic
Press Function Display Diagnostic Function Description
1 ACM SELF TEST The ACM carries out a self-test. At the end of the
Self-Test self-test, the display either indicates SELF PASS or
scrolls through any DTCs present. Note that the self-test
may not indicate all DTCs that are present. If additional
DTCs are suspected, retrieve continuous and on-demand
DTCs using the scan tool.
2 View DTCs NO DTCS, or The ACM displays any DTCs that are present. To scroll
scrolls through through the DTCs, press the TUNE UP button. If no
DTCs DTCs are present, the display reads NO DTCS.
3 AM/FM SIGNAL ### The ACM displays the AM/FM antenna signal strength.
Antenna To run this test, the audio system should be in AM radio
Signal tuner mode before entering the ACM self-diagnostic
Strength mode.
4 Software SOFT LEVELS The ACM displays software levels for various
Levels components of the audio system. Knowing the software
levels may not aid diagnostics. Press the TUNE UP
button to scroll through the software levels.
5 Display Test DISPLAY All of the ACM display segments illuminate.
TEST, then all
segments
illuminate
6 Retrieve RADIO The ACM displays the ACM part number and various
ACM Part CONFIG configuration levels. Press the TUNE UP button to scroll
Number to the desired function.
Audio Control Module (ACM) Self-Diagnostic Mode 5877

5. To exit the self-diagnostic mode, turn the ACM off.
Satellite Radio Electronic Serial Number (ESN) Retrieval - Vehicles Without Navigation
NOTE: If the SDARS is inoperable the Electronic Serial Number (ESN) may be obtained from a label affixed
to the chassis.
1. Operate the audio system in satellite radio mode.
2. Depending on vehicle configuration, press and hold the AUX button and preset button 1 or the
SIRIUS button and preset button 1, simultaneously.
• The Satellite Digital Audio Receiver System (SDARS) module Electronic Serial Number
(ESN) displays on the screen.
3. Record the SDARS module ESN .
4. Turn the audio system off.
Audio Systems With Navigation
1. Turn the Audio Front Control Module (ACM) on.
2. Operate the audio system in radio tuner (AM/FM) mode.
3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins.
• The display indicates each speaker as it is tested.
4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after this step,
or by allowing the speaker walk test to complete on its own.
Before the speaker walk test is complete, press the "End Test" selection.
5. The following tests are available through the "BEZEL DIAGNOSTICS" menu:
Display
Selection Diagnostic Function Description

On Demand The ACM carries out a self-test. At the end of the self-test, the display either
Self Test indicates "Test Passed" or lists any DTCs present. Note that the self-test may not
indicate all DTCs that are present. If DTCs are suspected, retrieve continuous and
on-demand DTCs using the scan tool.
View DTCs The ACM displays any DTCs that are present. If there is more than a full screen of
DTCs present, to scroll through the DTCs, press the down arrow on the display. If no
DTCs are present, the display reads NO DTCS. Press the "Clear DTCs" selection to
clear any DTCs present.
Configuration The display shows the ACM configuration. A "0" indicates the item is configured
Status off, while a "1" indicates the item is configured on. If the ACM appears to be
misconfigured, refer to Section 418-01 .
System Info The ACM displays system information for various components of the audio system.
The following items are most important for servicing the audio system:
• Nav Radio Part Number - provides the ACM part number
• ESN1 - provides the satellite radio Electronic Serial Number (ESN)
GPS Info The current Global Positioning System (GPS) satellite information is shown, along
with the current vehicle position. Pressing the "SV Status" selection provides
additional information, if present.
Speaker Walk The ACM carries out the speaker walk test.
Test
DVD The ACM tests the internal CD/DVD drive mechanism.
Mechanism
Test
Display Test This test provides for testing of the touchscreen colors and the touchscreen sectors.
Pressing any of the colors on the display causes the whole display to change to that
color; pressing the display again returns to the Display Test menu. Pressing the
"Touchscreen Activation Test" selection enters the touchscreen sector test. Press any
area of the screen to test the touchscreen sector; press the "X" at the RH lower corner
of the display to return to the Display Test menu.
Hardkey Test This test provides for testing of the ACM buttons (not the touchscreen). When each
button is pressed, the screen displays the button that is active. This test can also be
used to isolate a stuck button.
Radio Signal The ACM displays the AM/FM antenna signal strength. To run this test, the audio
Strength system should be in AM radio tuner mode before entering the ACM self-diagnostic
mode.
HDD Test The ACM tests its internal hard drive.
Sensor I/O The ACM displays inputs it is receiving from external sources. These inputs include:
Status • Ignition - indicates ON (ignition in ACC or RUN) or OFF
• Brake - indicates ON (vehicle in PARK) or OFF (vehicle not in PARK)
• Illumination - indicates ON or OFF
• ReverseGear - indicates ON (vehicle in REVERSE) or OFF (vehicle not in
REVERSE)
Microphone The ACM tests the microphone by supplying a test tone and monitoring the input
Test from the microphone. If there is a concern with the microphone input, the ACM sets
DTC B1D79:01. For diagnostics, refer to Diagnosis and Testing in this section.
SDARS Signal The ACM displays the satellite radio antenna signal strength.
Strength
6. To exit the self-diagnostic mode, press the "Exit Diagnostics" selection from the "BEZEL
DIAGNOSTICS" menu.


Accessory Protocol Interface Module (APIM) Software Level Check
Special Tool(s)

Universal Serial Bus (USB) Male-A to
Male-A Cable
CCMUSB2-AM-AM-10 or equivalent
NOTE: This procedure applies to checking the Accessory Protocol Interface Module (APIM) software level.
To program the APIM , refer to Accessory Protocol Interface Module (APIM) Programming in Section
418-01 .
1. Turn the Audio Front Control Module (ACM) on.
2. Connect the scan tool to the Data Link Connector (DLC).
3. Connect one end of the Universal Serial Bus (USB) male-A to male-A cable to the scan tool.
4. Connect the other end of the USB male-A to male-A cable to the vehicle USB port.
5. From the technician service publication website, run On-Line Automotive Service Information
System (OASIS) using Quick Start or by manually entering the Vehicle Identification Number (VIN).
6. From the OASIS tab, select the "Sync/APIM" bullet.
7. Select the "Read APIM" button to verify the current APIM software level.
• The display shows both the Vehicle Interface Processor (VIP) and Consumer Interface
Processor (CIP) software levels.
8. The scan tool displays the following information:

• Last Recorded State - Hardware
♦ VIN : vehicle identification number associated with the current APIM
♦ Installed date: date the APIM was installed
♦ Radio: currently identified ACM in the vehicle
♦ HW Part No.: APIM hardware part number
♦ Un-installed date: date (if any) the APIM was uninstalled
♦ S/N: APIM serial number
• Last Recorded State - Software
♦ Date/Time: date and time of last recorded software installation
♦ VIP : VIP software that was installed at that time
♦ CIP : CIP software that was installed at that time
♦ Description: a description of the content of the software revision
• History - Software
♦ Date/Time: date and time of any recorded software installation
Accessory Protocol Interface Module (APIM) Software Level Check 5881

♦ VIP : VIP software that was installed at that time
♦ CIP : CIP software that was installed at that time
• Available Software for Programming
♦ Select: allows the software package to be selected
♦ Lineage: the original software release, if the software available is a revision
♦ VIP : VIP software level that is available with the selection
♦ CIP : CIP software level that is available with the selection
9. Click a CIP software level to view the device compatibility list associated with the CIP software level,
if desired.
10. To exit the APIM software level check, disconnect the scan tool from the DLC and the USB port, or
exit the OASIS screen.
Accessory Protocol Interface Module (APIM) Software Level Check 5882

Antenna - AM/FM
NOTE: Combination AM/FM/satellite antenna shown, others similar.

1 - Antenna cable bolt (part of 18812)
2 18936 Antenna
3 18813 Antenna mast
1. Remove the LH and RH assist handles. For additional information, refer to Headliner in Section
501-05 .
2. Remove the LH and RH C-pillar trim panels. For additional information, refer to Section 501-05 .
3. Carefully lower the rear of the headliner to gain access to the antenna.
4. Loosen the antenna cable bolt and disconhe cable from the antenna.
5. Remove the antenna.

• Remove the antenna mast, if equipped.
• Press the 2 tabs and remove the antenna.
Antenna - AM/FM 5883

Antenna - AM/FM 5884

Antenna - AM/FM/Satellite Radio/Navigation

1 18813 Antenna mast
2 18936 Antenna
3 - Antenna retaining clip
4 - Antenna cable bolt (part of 18812)
1. Remove the LH and RH D-pillar trim panels. For additional information, refer to Section 501-05 .
2. Remove the rear dome lamp. For additional information, refer to Interior Lamp in Section 417-02 .
3. Carefully lower the rear of the headliner to gain access to the antenna.
Remove the antenna cable bolt and retaining clip from the antenna.
5. Disconnect the antenna cable connectors.

• Press the 2 tabs and remove the antenna.
Antenna - AM/FM/Satellite Radio/Navigation 5885

Antenna - AM/FM/Satellite Radio/Navigation 5886

Antenna - Satellite Radio
NOTE: Combination AM/FM/satellite antenna shown, others similar.

1 - Satellite radio antenna cable bolt (part of 18812)
2 18936 Satellite radio antenna
3 18813 Antenna mast (if equipped)
NOTE: This procedure applies to the stand-alone satellite radio antenna, the combination AM/FM/satellite
radio antenna, and the combination satellite radio/Global Positioning System (GPS) antenna.
1. Remove the LH and RH assist handles. For additional information, refer to Headliner in Section
501-05 .
2. Remove the LH and RH C-pillar trim panels. For additional information, refer to Section 501-05 .
3. Carefully lower the rear of the headliner to gain access to the satellite radio antenna.
4. Loosen the satellite radio antenna cable bolt and disconnect the cable from the antenna.

• Press the 2 tabs and remove the satellite radio antenna.
Antenna - Satellite Radio 5887

Antenna - Satellite Radio 5888

Antenna Module

1 19C029 Antenna module
2 - Antenna module-to-antenna connector (part of
19C029)
3 - Heated rear window connectors (part of 19C029)
4 - Antenna module electrical connectors (part of 14A005)
5 - Antenna module bolt
1. Remove the RH C-pillar trim panel. For additional information, refer to Section 501-05 .
2. Disconnect the antenna module connectors.

• Disconnect the antenna cable-to-antenna module connector.
• Disconnect the antenna module electrical connectors.
• Disconnect the antenna module-to-antenna connector.
3. Remove the bolt and the antenna module.

Antenna Module 5889

Antenna Module 5890

Antenna Cable - AM/FM
NOTE: Only the front AM/FM antenna cable is shown.
Part
1 18812 Front AM/FM antenna cable
2 - Front-to-rear AM/FM antenna cable connection (part of
18812)
3 18812 Rear AM/FM antenna cable
Removal
NOTE: Both the front and rear AM/FM antenna cables are part of the vehicle wiring harness. Because the
cables cannot be removed from the harness, this procedure applies to replacement of the cables only.
Front cable
1. Remove the Audio Front Control Module (ACM). For additional information, refer to Audio Control
Module (ACM) - Fusion or Audio Control Module (ACM) - MKZ in this section. >
Rear cable
2. Remove the RH front and RH rear sill panels by pulling straight upward.
3. NOTE: For MKZ, it is only necessary to remove the RH C-pillar trim panel.
Remove the LH and RH assist handles, and the LH and RH C-pillar trim panels. For
4. NOTE: For Fusion, it is necessary to loosen the antenna cable bolt.
Disconnect the rear AM/FM antenna cable from the AM/FM antenna (Fusion) or the antenna
module (MKZ).
5. Remove the enable circuit.
1. Disconnect C237 at the RH kick panel.
2. Remove the pin retainer from the inside of the male side of the connector by pulling
straight out with pliers.
Antenna Cable - AM/FM 5891

3. Using a suitable tool such as a straight pick, release the locking tab and remove the
enable circuit CME44 (BU) from C237-25.
4. Cut the existing circuit end and secure it with electrical tape.
Both cables
6. Disconnect the front-to-rear AM/FM antenna cable connection at the RH kick panel.
7. Cut the ends of the existing cable and tape them back to prevent NVH concerns.
Installation
Both cables
1. Overlay the new AM/FM antenna cable on the vehicle wiring harness, following the routing
of the original cable.
2. Secure the new AM/FM antenna cable with tape or zip ties, as necessary.
3. Connect the front-to-rear AM/FM antenna cable connection at the RH kick panel.
Front cable
4. Connect the front AM/FM antenna cable to the ACM .

5. Install the ACM . For additional information, refer to Audio Control Module (ACM) - Fusion
or Audio Control Module (ACM) - MKZ in this section.
Rear cable
6. Install the enable circuit.

1. Insert the enable circuit CME44 (BU) into C237-25.
2. Install the pin retainer into the inside of the male side of the connector.
3. Connect C237.
7. Connect the rear AM/FM antenna cable to the AM/FM antenna (Fusion) or the antenna
module (MKZ).
• For Fusion, tighten the bolt to 8 Nm (71 lb-in).
8. NOTE: For MKZ, only the RH C-pillar trim panel was removed.
Install the LH and RH assist handles, and the LH and RH C-pillar trim panels. For
additionnformation, refer to Section 501-05 .
9. Install the RH front and RH rear sill panels.


Antenna Cable - Satellite Radio
NOTE: The front satellite radio antenna cable with navigation is shown.

1 18812/10E928 Front satellite radio antenna cable (without navigation/
with navigation)
2 - Front-to-rear satellite radio antenna cable connection
(part of 18812/ 10E928)
3 18812 Rear satellite radio antenna cable
Removal
NOTE: Both the front and rear satellite radio antenna cables are part of the vehicle wiring harness. Because
the cables cannot be removed from the harness, this procedure applies to replacement of the cables only.
NOTE: For vehicles with navigation, a splitter is built-in to the front satellite radio antenna cable to split the
satellite radio and Global Positioning System (GPS) signals.
Front cable
Module (ACM) - Fusion or Audio Control Module (ACM) - MKZ in this section.
Rear cable
2. Remove the RH front and RH rear sill panels by pulling straight upward.
3. Remove the LH and RH assist handles, and the LH and RH C-pillar trim panels. For additional
4. Loosen the antenna cable bolt and disconnect the cable from the antenna.
5. Remove the enable circuit.

1. Disconnect C237 at the RH kick panel.
Antenna Cable - Satellite Radio 5894

2. Remove the pin retainer from the inside of the male side of the connector by pulling straight
out with pliers.
3. Using a suitable tool such as a straight pick, release the locking tab and remove the enable
circuit CME44 (BU) from C237-25.
4. Cut the existing circuit end and secure it with electrical tape.
Both cables
6. Disconnect the front-to-rear satellite radio antenna cable connection at the RH kick panel.
7. Cut the ends of the existing cable and tape them back to prevent NVH concerns.
Installation
Both cables
1. Overlay the new satellite radio antenna cable on the vehicle wiring harness, following the routing othe
original cable.
2. Secure the new AM/FM antenna cable with tape or zip ties, as necessary.
• For the front satellite radio antenna cable on vehicles with navigation, secure the splitter using
the built-in push-pins.
3. Connect the front-to-rear satellite radio antenna cable connection at the RH kick panel.
Front cable
4. Connect the front AM/FM antenna cable to the ACM .
5. Install the ACM . For additional information, refer to Audio Control Module (ACM) - Fusion or
Audio Control Module (ACM) - MKZ in this section.
Rear cable
6. Install the enable circuit.

1. Insert the enable circuit CME44 (BU) into C237-25.
2. Install the pin retainer into the inside of the male side of the connector.
3. Connect C237.
7. Connect the rear satellite radio antenna cable to the antenna.

♦ Tighten the bolt to 8 Nm (71 lb-in).
8. Install the LH and RH assist handles, and the LH and RH C-pillar trim panels. For additional
9. Install the RH front and RH rear sill panels.


Audio Digital Signal Processing (DSP) Module
Sony® Sound

1 W505423-S Audio Digital Signal Processing (DSP) module
bolts (3 required)
2 - Audio DSP module electrical connectors (part
of 14A005)
3 18B849 Audio DSP module
THX® Sound
Part
1 W505423-S Audio Digital Signal Processing (DSP) module bolts (3
required)
2 - Audio DSP module electrical connectors (part of
Audio Digital Signal Processing (DSP) Module 5897

14A005)
3 18B849 Audio DSP module
4 5445422 RH luggage compartment trim panel
NOTE: This procedure applies to Fusion with Sony® sound and MKZ with THX® sound only. For all other
amplifiers, refer to the appropriate procedure in this section.
1. NOTE: Module configuration is required wew audio Digital Signal Processing (DSP) module is
being installed.
Upload the audio DSP module configuration information to the scan tool. For additional information,
refer to Programmable Module Installation (PMI) in Section 418-01 .
2. Remove the 4 pushpins and the RH luggage compartment trim panel.
3. Disconnect the audio DSP module electrical connectors.
4. Remove the 3 bolts and the audio DSP module.


• Download the configuration information to the audio DSP module. For additional
information, refer to PMI in Section 418-01 .
THX® Sound 5898

Audio Input Jack
NOTE: Stowage bin door shown removed for clarity.
NOTE: Vehicle with the SYNC® system shown, others similar.
NOTE: Fusion shown, MKZ similar.
Part
1 - Audio input jack bezel
2 - Universal Serial Bus (USB) cable and port (if equipped)
(part of 14D202)
3 19A164 Audio input jack
1. Open the floor console stowage bin door.
2. Using a suitable tool, remove the audio input jack bezel by prying straight back (Fusion) or straight up
(MKZ).
• Disconnect the Universal Serial Bus (USB) cable and port, if equipped.
3. Release the tabs and remove the audio input jack.
Audio Input Jack 5899

Audio Input Jack 5900

Audio Amplifier

1 W505423-S Audio amplifier bolts (3 required)
2 - Audio amplifier electrical connectors (part of
14A005)
3 18B849 Audio amplifier
NOTE: This procedure applies to the MKZ with Premium Sound only. For all other amplifiers, refer to the
appropriate procedure in this section.
2. Disconnect the audio amplifier electrical connectors.
3. Remove the 3 bolts and the audio amplifier.

Audio Amplifier 5901

Audio Amplifier 5902

Audio Control Module (ACM) - Fusion
NOTE: Without navigation shown, with navigation similar.

1 W707628 Audio Front Control Module (ACM) screws (4
required)
2 18806 ACM
3 - ACM electrical connectors (part of 14401)
NOTE: It is not necessary to remove the Audio Front Control Module (ACM) to retrieve the part number. For
additional information, refer to Audio Control Module (ACM) Self-Diagnostic Mode in this section.
All vehicles
1. NOTE: Module configuration is required when a new ACM is being installed.
Upload the ACM configuration information to the scan tool. For additional information, refer to
Programmable Module Installation (PMI) in Section 418-01 .
Vehicles with navigation
2. Remove the Front Display Interface Module (FDIM). For additional information, refer to Front
Display Interface Module (FDIM) - Fusion in this section.
Vehicles without navigation
3. Remove the instrument panel center finish panel. For additional information, refer to Section 501-12 .
All vehicles
4. NOTE: For vehicles with navigation, the 2 upper screws were removed with the FDIM .
Remove the 4 screws (2 for navigation) and the ACM .
Audio Control Module (ACM) - Fusion 5903


• Download the ACM configuration information from the scan tool. For additional information,
refer to PMI in Section 418-01 .
Audio Control Module (ACM) - Fusion 5904

Audio Control Module (ACM) - MKZ

1 - Audio Front Control Module (ACM) screws (8
required)
2 18806 ACM
3 18842 Front Controls Interface Module (FCIM)
NOTE: It is not necessary to remove the Audio Front Control Module (ACM) to retrieve the part number. For
additional information, refer to Audio Control Module (ACM) Self-Diagnostic Mode in this section.
1. NOTE: Module configuration is required when a new ACM is being installed.
Upload the ACM configuration infor to the scan tool. For additional information, refer to
Programmable Module Installation (PMI) in Section 418-01 .
2. Remove the Front Controls Interface Module (FCIM). For additional information, refer to Front
Controls Interface Module (FCIM) - MKZ in this section.
3. Remove the 8 screws and the ACM .

• Download the ACM configuration information from the scan tool. For additional information,
refer to PMI in Section 418-01 .
Audio Control Module (ACM) - MKZ 5905

Audio Control Module (ACM) - MKZ 5906

Front Controls Interface Module (FCIM) - Fusion

1 - Instrument panel center finish panel
3 W506943-S Front Controls Interface Module (FCIM) screws (12
required)
3 18842 FCIM
2. Remove the 12 screws and the FCIM .
Front Controls Interface Module (FCIM) - Fusion 5907

Front Controls Interface Module (FCIM) - Fusion 5908

Front Controls Interface Module (FCIM) - MKZ
Floor Console and Instrument Panel Components

1 - Audio Front Control Module (ACM) screws (8
required)
2 18806 ACM
3 18842 Front Controls Interface Module (FCIM)
1. Remove the LH and RH floor console finish mouldings. For additional information, refer to Console -
Floor, MKZ in Section 501-12 .
2. Remove the instrument panel finish moulding. For additional information, refer to Instrument Panel -
Exploded View in Section 501-12 .
3. Remove the 4 screws and the Front Controls Interface Module (FCIM).
Front Controls Interface Module (FCIM) - MKZ 5909

4. Remove the 8 screws and separate the Audio Front Control Module (ACM) from the FCIM .
Floor Console and Instrument Panel Components 5910

Front Display Interface Module (FDIM) - Fusion
NOTE: Without navigation shown, with navigation similar.

1 W707628-S Front Display Interface Module (FDIM) screws (4
required)
2 10D885/10E899 FDIM (without navigation/ with navigation)
3 - FDIM electrical connector (part of 14401)
NOTE: Vehicles without navigation require Programmable Module Installation (PMI) when a new module is
being installed. For vehicles without navigation, the Front Display Interface Module (FDIM) is not a
stand-alone module.
1. For vehicles without navigation, upload the FDIM configuration information to the scan tool. For
additional information, refer to PMI in Section 418-01 .
3. NOTICE: For vehicles with navigation, make sure not to bend the video cable when removing
the FDIM .
Remove the 4 screws and the FDIM .

• For vehicles without navigation, download the configuration information to the FDIM . For
Front Display Interface Module (FDIM) - Fusion 5911

Front Display Interface Module (FDIM) - Fusion 5912

Front Display Interface Module (FDIM) - MKZ
NOTE: With navigation shown, without navigation similar.

1 W707628-S Front Display Interface Module (FDIM) screws (4
required)
2 10D885/10E899 FDIM (without navigation/ with navigation)
3 - FDIM electrical connector (part of 14401)
NOTE: Vehicles without navigation require Programmable Module Installation (PMI) when a new module is
being installed. For vehicles without navigation, the Front Display Interface Module (FDIM) is not a
stand-alone module.
1. For vehicles without navigation, upload the FDIM configuration information to the scan tool. For
3. NOTICE: For vehicles with navigation, make sure not to bend the video cable when removing
the FDIM .
Remove the 4 screws and the FDIM .

• For vehicles without navigation, download the configuration information to the FDIM . For
Front Display Interface Module (FDIM) - MKZ 5913

Front Display Interface Module (FDIM) - MKZ 5914

Global Positioning System Module (GPSM) - Fusion
NOTE: Steering wheel shown removed for clarity only.
Part
1 - Global Positioning System Module (GPSM) electrical
connector
2 10E893 GPSM
1. Remove the Instrument Panel Cluster (IPC). For additional information, refer to Section 413-01 .
2. Release the clips and remove the Global Positioning System Module (GPSM).
Global Positioning System Module (GPSM) - Fusion 5915

Global Positioning System Module (GPSM) - Fusion 5916

Global Positioning System Module (GPSM) - MKZ

1 W707628 Bolt
2 10E893 Global Positioning System Module (GPSM)
3 - GPSM electrical connector
1. Remove the instrument panel speaker. For additional information, refer to Section 415-00 .
2. Remove the Global Positioning System Module (GPSM) mounting bolt.
3. Remove the GPSM .

&nbP>
Global Positioning System Module (GPSM) - MKZ 5917

Global Positioning System Module (GPSM) - MKZ 5918

Speaker - Door
NOTE: Fusion shown, MKZ similar
NOTE: Front door shown, rear door similar.
Part
1 - Sail panel
2 - Front door tweeter speaker electrical connector (part of
18808)
3 18808 Door speaker
4 - Door speaker screws (4 required)
5 - Door speaker electrical connectors (part of
14630/14631)
All speakers
1. Remove the door trim panel. For additional information, refer to Section 501-05 .
Front door tweeter speaker (Fusion)
2. Remove the sail panel.

3. Remove the 2 screws and the front door tweeter speaker from the sail panel.
Speaker - Door 5919

Front door tweeter speaker (MKZ)
4. Remove the 2 nuts and the front door tweeter speaker from the door trim panel.
Front or rear door speaker
5. Remove the 4 screws and the door speaker.

All speakers
Speaker - Door 5920

Speaker - Instrument Panel
NOTE: Vehicle without THX® shown, vehicles with THX® similar.
Part
1 5413594 Instrument panel speaker cover
2 W707628-S Instrument panel speaker screws (Vehicles without
THX® - 2 required, THX® - 3 required)
3 18978/18808 Instrument panel speaker (Sony®/THX®)
4 - Instrument panel speaker electrical connector (part of
14401)
1. NOTE: For THX® sound, release the top 2 retaining clips of the center instrument panel finish panel
to allow clearence for speaker cover removal.
NOTE: For THX® sound, pry the speaker cover at the front, then lift.
Using a suitable tool such as a trim removal tool, remove the instrument panel speaker cover.
2. Remove the screws (2 for vehicles without THX® sound, 3 for THX® sound) and the instrument
panel speaker.
Speaker - Instrument Panel 5921

Speaker - Instrument Panel 5922

Speaker - Parcel Shelf

1 - Parcel shelf speaker screws (3 required)
2 18808 Parcel shelf speaker
3 - Parcel shelf speaker electrical connector (part of
14A005)
2. Remove the 3 screws and the parcel shelf speaker.

Speaker - Parcel Shelf 5923

Speaker - Parcel Shelf 5924

Speaker - Quarter Panel

1 W709996 Quarter panel speaker screws (4 required)
2 18808 Quarter panel speaker
3 - Quarter panel speaker electrical connector
(part of 14A005)
4 W701930 Quarter panel speaker mounting bracket
screws (3 required)
1. Remove the quarter trim panel. For additional information, refer to Section 501-05 .
2. Remove the 4 screws and the quarter panel speaker.

Speaker - Quarter Panel 5925

Speaker - Quarter Panel 5926

Steering Wheel Controls
Fusion
Part
1 9C888 Steering wheel controls
2 - Steering wheel controls electrical connector (part of
14A411)
MKZ
Part
1 - Steering wheel controls bezel screws (4 required)
2 - Steering wheel controls bezel
3 9C888 Steering wheel controls
4 - Steering wheel controls electrical connector (part of
14A411)
MKZ
Steering Wheel Controls 5927

2. Remove the 4 screws and the steering wheel controls bezel.
All vehicles
3. Remove the steering wheel controls by pulling the switch toward the rear of the vehicle.
4. Remove the steering wheel controls bezel, if equipped.
MKZ 5928
Speaker - Subwoofer
NOTE: RH side shown, LH side similar.

1 - Subwoofer speaker screws (4 required)
2 18808 Subwoofer speaker
3 - Subwoofer speaker electrical connector (part of
14A005)
2. Remove the 4 screws and the subwoofer speaker.

Speaker - Subwoofer 5929

Speaker - Subwoofer 5930

Accessory Protocol Interface Module (APIM)
Part
1 - Floor console rear trim panel (part of 045A36)
2 W505060-S Accessory Protocol Interface Module (APIM) screws (2
required (Fusion), 4 required (MKZ))
3 14D212 APIM
4 14D202 Universal Serial Bus (USB) cable
5 - APIM electrical connector (part of 14B079)
1. NOTE: It is necessary to record the current Accessory Protocol Interface Module (APIM) software
and hardware level when a new APIM is being installed to make sure that the new component is the
same version as the component being replaced.
Retrieve and record the current APIM software and hardware level. For additional information,
Accessory Protocol Interface Module (APIM) Software Level Check in this section.
2. Remove the floor console rear trim panel by pulling out at the botto disengage the clips then rotating
the bottom of the panel out to release the upper retaining tabs.
3. NOTE: For Fusion, the APIM is removed as an assembly with the bracket.
Remove the 2 screws (Fusion) or 4 screws (MKZ) and the APIM .
• Disconnect the APIM electrical connector.

• Disconnect the Universal Serial Bus (USB) cable.

• If a new APIM is being installed, program the APIM to the correct software level. For
additional information, refer to Accessory Protocol Interface Module (APIM) Programming
Accessory Protocol Interface Module (APIM) 5931

in Section 418-01 .
Accessory Protocol Interface Module (APIM) 5932

Universal Serial Bus (USB) Cable and Port
Part
1 - Floor console rear trim panel (part of 045A36)
2 - Universal Serial Bus (USB) cable and port-to-bezel
connector (part of 14D202)
3 14D202 USB cable and port
1. Remove the floor console. For additional information, refer to Section 501-12 .
2. Disconnect the Universal Serial Bus (USB) cable and port-to-bezel connector.
3. Remove the floor console rear trim panel by pulling straight back to disengage the clips.
4. NOTICE: Be careful not to flex the floor console RH side panel too much, or damage to the floor
console may occur.
Remove the USB cable and port.
• Disconnect the USB cable and port-to-Accessory Protocol Interface Module (APIM)
• Carefully flex the floor console RH side panel and remove the USB cable and port.
Universal Serial Bus (USB) Cable and Port 5933

&nbs
Universal Serial Bus (USB) Cable and Port 5934

Video Cable

1 10E929 Video cable
Module (ACM) - Fusion or Audio Control Module (ACM) - MKZ in this section.
2. Remove the video cable.

• Secure the video cable using tape or zip-ties, as necessary.
Video Cable 5935

Microphone

1 19A391 Microphone
Removal
NOTE: If the microphone is removed from the headliner, a new microphone must be installed.
1. Using a suitable tool, (such as a thin small flat head screwdriver) twist and pry the microphone bezel
from the headliner metal mounting bracket.
2. Remove the microphone from the headliner by grasping the microphone pigtail.
• Disconnect the microphone electrical connector.
Installation
1. Reconnect the microphone electrical connector.
2. Wrap the connection with anti-rattle tape.
3. Feed the microphone pigtail into the headliner through the microphone hole.
• Verify the microphone pigtail points towards the front of the vehicle.
4. Snap the microphone into the headliner mounting bracket.

• Verify the mounting bracket and microphone are snug to the headliner.
Microphone 5936
Microphone 5937
Subwoofer Amplifier
Part
1 W503924 Subwoofer amplifier screws (3 required)
2 - Subwoofer amplifier electrical connectors (part of
14A005)
3 18B849 Subwoofer amplifier
4 N802734 RH luggage compartment trim panel pushpins (4
required)
5 5445422 RH luggage compartment trim panel
NOTE: Make sure the key is in the OFF position.
2. Disconnect the subwoofer amplifier electrical connectors.
3. Remove the 3 screws and the subwoofer amplifier.

Subwoofer Amplifier 5938


2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 00: Service Information
SECTION 100-00: Service Information
SECTION 100-01: Identification Codes
SECTION 100-02: Jacking and Lifting
SECTION 100-03: Maintenance Schedule
SECTION 100-04: Noise, Vibration and Harshness

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 01: Body
SECTION 501-00: Body System - General Information
SECTION 501-02: Front End Body Panels
SECTION 501-03: Body Closures
SECTION 501-05: Interior Trim and Ornamentation
SECTION 501-08: Exterior Trim and Ornamentation
SECTION 501-09: Rear View Mirrors
SECTION 501-10: Seating
SECTION 501-11: Glass, Frames and Mechanisms
SECTION 501-12: Instrument Panel and Console
SECTION 501-14: Handles, Locks, Latches and Entry Systems
SECTION 501-16: Wipers and Washers
SECTION 501-17: Roof Opening Panel
SECTION 501-19: Bumpers
SECTION 501-20A: Safety Belt System
SECTION 501-20B: Supplemental Restraint System
SECTION 501-35: Body Repairs

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 02: Frame and Mounting
SECTION 502-00: Uni-Body, Subframe and Mounting System

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 03: Engine
SECTION 303-00: Engine System - General Information
SECTION 303-01A: Engine - 2.5L
SECTION 303-01B: Engine - 3.0L (4V)
SECTION 303-01C: Engine - 3.5L
SECTION 303-01D: Engine - 2.5L Hybrid
SECTION 303-03A: Engine Cooling
SECTION 303-03B: Engine Cooling - Hybrid
SECTION 303-04A: Fuel Charging and Controls - 2.5L
SECTION 303-04B: Fuel Charging and Controls - 3.0L (4V)
SECTION 303-04C: Fuel Charging and Controls - 3.5L
SECTION 303-04D: Fuel Charging and Controls - Hybrid
SECTION 303-05A: Accessory Drive - 2.5L
SECTION 303-05B: Accessory Drive - 3.0L (4V)
SECTION 303-05C: Accessory Drive - 3.5L
SECTION 303-05D: Accessory Drive - Hybrid
SECTION 303-06: Starting System
SECTION 303-07A: Engine Ignition - 2.5L
SECTION 303-07B: Engine Ignition - 3.0L (4V)
SECTION 303-07C: Engine Ignition - 3.5L
SECTION 303-08A: Engine Emission Control - 2.5L
SECTION 303-08B: Engine Emission Control - 3.0L (4V)
SECTION 303-08C: Engine Emission Control - 3.5L
SECTION 303-08D: Engine Emission Control - Hybrid

SECTION 303-12A: Intake Air Distribution and Filtering - 2.5L
SECTION 303-12B: Intake Air Distribution and Filtering - 3.0L (4V)
SECTION 303-12C: Intake Air Distribution and Filtering - 3.5L
SECTION 303-12D: Intake Air Distribution and Filtering - Hybrid
SECTION 303-13A: Evaporative Emissions
SECTION 303-13B: Evaporative Emissions - Hybrid
SECTION 303-14A: Electronic Engine Controls - 2.5L
SECTION 303-14B: Electronic Engine Controls - 3.0L (4V)
SECTION 303-14C: Electronic Engine Controls - 3.5L
SECTION 303-14D: Electronic Engine Controls - Hybrid

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 04: Suspension
SECTION 204-00: Suspension System - General Information
SECTION 204-01: Front Suspension
SECTION 204-02: Rear Suspension
SECTION 204-04: Wheels and Tires

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 05: Driveline
SECTION 205-00: Driveline System - General Information
SECTION 205-01: Driveshaft
SECTION 205-02: Rear Drive Axle/Differential
SECTION 205-04: Front Drive Halfshafts
SECTION 205-05: Rear Drive Halfshafts

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 06: Brake System
SECTION 206-00: Brake System - General Information
SECTION 206-03: Front Disc Brake
SECTION 206-04: Rear Disc Brake
SECTION 206-05: Parking Brake and Actuation
SECTION 206-06: Hydraulic Brake Actuation
SECTION 206-07: Power Brake Actuation
SECTION 206-09: Anti-Lock Brake System (ABS) and Stability Control

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 07: Automatic Transmission
SECTION 307-01A: Automatic Transaxle/Transmission - Aisin AW21
SECTION 307-01B: Automatic Transaxle/Transmission - 6F35
SECTION 307-01C: Automatic Transaxle/Transmission - Electronically Controlled Continuously Variable

Transmission (eCVT)
SECTION 307-02A: Transaxle/Transmission Cooling - Aisin AW21/6F35
SECTION 307-02B: Transaxle/Transmission Cooling - Hybrid
SECTION 307-05A: Automatic Transaxle/Transmission ontrols - Aisin AW21/6F35
SECTION 307-05B: Automatic Transaxle/Transmission External Controls - Hybrid

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 08: Manual Transmission, Clutch and Transfer Case
SECTION 308-00: Manual Transaxle/Transmission and Clutch - General Information
SECTION 308-03: Manual Transaxle/Transmission
SECTION 308-06: Manual Transaxle/Transmission External Controls
SECTION 308-07A: Four Wheel Drive (4WD) Systems
SECTION 308-07B: Transfer Case - Power Transfer Unit (PTU)

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 09: Exhaust System

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 10: Fuel System
SECTION 310-00: Fuel System - General Information
SECTION 310-01B: Fuel Tank and Lines - Hybrid
SECTION 310-02: Acceleration Control

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 11: Steering System
SECTION 211-00A: Steering System - Electronic Power Assist Steering (EPAS)
SECTION 211-00B: Steering System - Hydraulic Power Assist Steering (HPAS)
SECTION 211-05: Steering Column Switches

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 12: Climate Control System
SECTION 412-00A: Climate Control System - General Information and Diagnostics
SECTION 412-00B: Climate Control System - General Information and Diagnostics - Hybrid

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 13: Instrumentation and Warning Systems
SECTION 413-00: Instrument Cluster and Panel Illumination
SECTION 413-01: Instrumentation, Message Center, and Warning Chimes

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 14: Battery and Charging System
SECTION 414-05: High Voltage Converter/Inverter

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 15: Audio Systems
SECTION 415-00: Information and Entertainment Systems

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 17: Lighting
SECTION 417-01: Exterior Lighting
SECTION 417-02: Interior Lighting

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 18: Electrical Distribution
SECTION 418-00: Module Communications Network
SECTION 418-01: Module Configuration

2012 Fusion,
MKZ, Fusion
Hybrid, MKZ
Hybrid
Contents/Index
GROUP 19: Electronic Feature Group
SECTION 419-01A: Anti-Theft - Perimeter
SECTION 419-01B: Anti-Theft - Passive Anti-Theft System (PATS)
SECTION 419-01C: Anti-Theft - Passive Anti-Theft System (PATS) - Hybrid
SECTION 419-02: Remote Convenience
SECTION 419-03: Cruise Control
SECTION 419-04: Side And Rear Vision
SECTION 419-10: Multifunction Electronic Modules


Manual

Headlamp bolts 3.7 - 33
Rear lamp assembly nuts 6 - 53
Reversing lamp switch 24 18 -

SECTION 417-01: Exterior 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop
Lighting Manual
DESCRIPTION AND
OPERATION
Exterior Lighting
NOTE: If equipped, the perimeter lighting feature can be enabled or disabled. When enabled, the exterior
lamps are illuminated when the UNLOCK button is pressed on the Remote Keyless Entry (RKE) transmitter.
Refer to Section 501-14 for programming and diagnostics.
Exterior Lighting System
The exterior lighting system consists of the following components:
• Headlamps
• Ballasts (if equipped with High Intensity Discharge (HID) headlamps) (located on the underside of
each headlamp)
• Front side marker lamps
• Rear side marker lamps
• Rear lamp assemblies
• High mounted stoplamp
• Reversing lamps
• Headlamp switch
• Hazard flasher lamp switch (located in front of the instrument panel storage bin for Fusion or the
lower portion of the center instrument panel finish panel for MKZ)
• Light sensor
• Stoplamp switch
• Reversing lamp switch (located on the forward side of the manual transaxle)
• SJB (located to the left of the brake pedal)
• Headlamp Control Module (HCM) (located next to the SJB )
Battery Saver
NOTE: Time-out is 1 minute if the vehicle has less than 80 km (50 miles).
The battery saver is internal to the SJB and provides automatic shut-off of the headlamps and parking lamps
after 10 minutes in order to save battery voltage. A timer is started when the ignition switch is turned to the
OFF position with the headlamp switch in the HEADLAMPS ON position, or the headlamp switch is placed
in the HEADLAMPS ON position with the ignition switch off. When the time-out period has elapsed, the
voltage is automatically shut off to the lamps by the battery saver.
The battery saver does not control the parking lamps if the headlamp switch is in the PARKING LAMPS ON
position.
Lamp Assembly Condensation
Exterior lamps are vented to accommodate normal changes in pressure. Condensation can be a natural
by-product of this design. When moist air enters the lamp assembly through the vents, there is a possibility
that condensation can occur if the temperature is cold. When normal condensation occurs, a thin film of mist
can form on the interior of the lens. The thin mist eventually clears and exits through the vents during normal
Exterior Lighting 5961

operation. Time to clear the lens of acceptable mist varies with ambient humidity and lamp types. Normal
condensation clears from any lamp in 48 hours under dry conditions.
Do not replace a lamp assembly with acceptable levels of condensation such as:
• presence of thin mist (no streaks, drip marks or droplets are present)
• fine mist covers less than 50% of the lens
Examples of unacceptable moisture (usually caused by a lamp housing leak):
• water puddling inside the lamp

• large water droplets, drip marks or streaks present on the interior of the lens
Headlamps - Fusion
The headlamp system is a quad-beam pattern system. It consists of replaceable low and high beam bulbs. The
headlamp assembly has the park/turn lamp integrated into the headlamp assembly.
If the headlamps are on when the ignition switch is turned off, the battery saver feature turns off the
headlamps after 10 minutes have elapsed.
When the low beams are requested (based on inputs to the SJB ), the low beams are illuminated.
When the high beams are requested, the high beams are illuminated with the low beams.
When the flash-to-pass feature is requested, the high beams are illuminated for as long as the multifunction
switch is held in the FLASH-TO-PASS position.
Headlamps - MKZ
The headlamp system is a quad-beam pattern system. It consists of replaceable low and high beam bulbs. The
headlamp assembly has the park/turn and side marker lamps integrated into the headlamp assembly.
If the headlamps are on when the ignition switch is turned off, the battery saver feature turns off the
headlamps after 10 minutes have elapsed.
When the high beams are requested, the high beams are illuminated with the low beams.
When the flash-to-pass feature is requested, the high beams are illuminated for as long as the multifunction
High Intensity Discharge (HID) Headlamps
Each HID headlamp consists of a ballast and replaceable low and higam bulbs. The ballasts provide the higher
voltage required for the HID bulbs to illuminate.
When the low beams are on, the HID ballasts provide high voltage to the HID bulbs.
Autolamps
The autolamp system provides light sensitive automatic on/off control of the exterior lamps. The autolamp
system keeps the exterior lamps on for a pre-selected period of time after the ignition switch is turned to the

OFF position (20 seconds is the factory default setting). The pre-selected time lapse is adjustable up to
approximately 3 minutes. To adjust the setting, refer to Autolamps Time Delay Adjustment in this section.
Headlamps On With Wipers On Feature
If the headlamp switch is in the AUTOLAMPS ON position, this feature turns the exterior lamps on when the
front wipers are on for more than 10 seconds (except during a mist wipe or while the wipers are on to clear
washer fluid during a wash condition). The exception to this is when the exterior lights are on because of
darkness determined by the autolamp system.
Refer to Section 501-16 for diagnostics of the headlamps on with wipers on feature.
Stoplamps
NOTE: The Fusion high mounted stoplamp has 9 LEDs mounted in the center third portion of the assembly.
The outer left and right portions of the high mounted stoplamp are not illuminated. The high mounted
stoplamp is not designed to illuminate the full width of the lens.
The stoplamp switch is located on the brake pedal assembly. The stoplamps are supplied voltage when the
brake pedal is applied.
Turn Signal/Hazard Lamps
The front turn signal lamps are located within the headlamp assemblies. Fusion utilizes combination stop/turn
lamps while MKZ has dedicated rear turn lamps. When the multifunction switch is placed in the LH or RH
TURN positions, the SJB routes voltage to the LH or RH turn signal lamps. The SJB then cycles the voltage
on and off approximately 80 times per minute. If a front or rear turn bulb is inoperative, the SJB cycles the
voltage on and off approximately 160 times per minute.
When the hazard switch is pressed, the SJB supplies voltage to all the turn lamps. The SJB cycles the voltage
on and off approximately 80 times per minute.
For Fusion, the hazard flasher lamp switch is mounted to the instrument panel upper storage compartment
panel.
For MKZ, the hazard flasher lamp switch is part of the Front Controls Interface Module (FCIM).
Parking Lamps
The SJB supplies voltage to the parking lamps when demanded. The parking lamps include the following:
• Front parking lamps

• Front side marker lamps
• Rear parking lamps
• Rear side marker lamps
• License plate lamps
Fog Lamps
The fog lamp switch is integrated into the headlamp switch. When the fog lamp switch is engaged, the SJB
provides ground for the fog lamp relay coil (integrated into the SJB ), which then energizes and routes voltage
to the fog lamps. The fog lamps can be turned on when the ignition is in run or accessory, the parking lamps
are on, and the high beam headlamps are off.

On vehicles equipped with HID headlamps, the fog lamps are used for the Daytime Running Lamps (DRL), if
this feature is enabled.
Reversing Lamps
When the transmission is placed in REVERSE (R), the reversing lamps are illuminated. The reversing lamps
are located within the rear lamp assemblies (Fusion) or mounted to the luggage compartment lid (MKZ).
Daytime Running Lamps (DRL)
On vehicles with halogen headlamps, the DRL system illuminates the low beam headlamps at a reduced
intensity.
On vehicles with HID headlamps, the DRL system operates the fog lamps at full intensity by energizing the
fog lamp relay.
The DRL turn on when the following conditions are met:
• The ignition switch is in the RUN position.

• The headlamps have not been turned on by the autolamp system or the headlamp switch.
• The transmission is not in PARK (P) (automatic transaxle).
• The parking brake is released (manual transaxle).
The SJB can be configured to turn the DRL on for this vehicle. Refer to Section 418-01 for additional
information on this programmable parameter.
Adaptive Headlighting
Vehicles equipped with adaptive front lighting have a Headlamp Control Module (HCM) to control the
left/right swiveling of the headlamp bulbs. Depending on the inputs received (steering wheel angle and
vehicle speed for example), the adaptive front lighting module HCM can change the angle at which the
headlamps are aimed (left or right) to improve nighttime visibility around curves.
The swiveling motor within each headlamp (used to control the angle of the headlamp beams) are part of the
headlamp assembly and cannot be repaired separately.



Manual
Diagnostic Trouble Code (DTC) Chart

B106E Solid State Driver The module has temporarily disabled an output because an
Disabled Due to Short excessive current draw exists (such as a short to ground). The
Circuit SJB cannot enable the output until the cause of the short is
corrected. ADDRESS all other DTCs first. After the cause of the
concern is corrected, CLEAR the DTCs. REPEAT the self-test.
B106F Module Disabled Due The module has permanently disabled an output because an
to External Fault excessive current draw fault (such as a short to ground) has
exceeded the limits that the SJB can withstand. The cause of the
excessive current draw MUST be corrected before a new SJB is
installed. ADDRESS all other DTCs first. After the cause of the
concern is corrected, INSTALL a new SJB . TEST the system for
normal operation.
B1472 Lamp Headlamp Input GO to Pinpoint Test D .
B1485 Brake Pedal Input Short GO to Pinpoint Test L .
to Battery
B1510 Flash To Pass Switch GO to Pinpoint Test E .
B1578 Lamp Park Input GO to Pinpoint Test R .
B1696 Autolamp On Circuit GO to Pinpoint Test H .
Short To Ground
B1791 Autolamp Sensor Input GO to Pinpoint Test H .
Circuit Open
B1793 Autolamp Sensor Input GO to Pinpoint Test H .
B2008 Wipers On Signal GO to Pinpoint Test H .
B2044 Left Rear Stop Lamp GO to Pinpoint Test J .
B2045 Left Rear Stop Lamp If the lamp is inoperative, GO to Pinpoint Test J .
Circuit Open
If the lamp is always on, GO to Pinpoint Test L .
B2046 Right Rear Stop Lamp GO to Pinpoint Test J .
B2047 Right Rear Stop Lamp If the lamp is inoperative, GO to Pinpoint Test J .
Circuit Open
If the lamp is always on, GO to Pinpoint Test L .
B2048 Left Rear Turn Lamp GO to Pinpoint Test O .

B2049 Left Rear Turn Lamp GO to Pinpoint Test O .

Circuit Open
B2050 Right Rear Turn Lamp GO to Pinpoint Test O .
B2051 Right Rear Turn Lamp GO to Pinpoint Test O .
Circuit Open
B2071 Hazard Switch Signal GO to Pinpoint Test P .
Short to Ground
B2254 Front Fog Lamp Switch GO to Pinpoint Test U .
Failure
B2281 Right Turn Switch GO to Pinpoint Test N .
Short to Ground
B2282 Left Turn Switch Short GO to Pinpoint Test N .
to Ground
B2498 Headlamp Switch ADDRESS any other DTCs first. GO to Pinpoint Test D .
Multiple Signals Input
Active
B2A22 Headlamp Off Circuit ADDRESS any other DTCs first. GO to Pinpoint Test D .
Open
B2A23 High Beam Input GO to Pinpoint Test E .
B2A24 Turn Signal Input DIAGNOSE all other DTCs and symptoms first. If no other DTCs or
Circuit Failure symptoms are present, INSTALL a new SJB . REFER to Section
B2A27 Right Front Turn Lamp GO to Pinpoint Test O .
Circuit Open
B2A28 Right Front Turn Lamp GO to Pinpoint Test O .
B2A29 Left Front Turn Lamp GO to Pinpoint Test O .
Circuit Open
B2A2A Left Front Turn Lamp GO to Pinpoint Test O .
B2A2B Left Corner Lamp DIAGNOSE all other DTCs and symptoms first. If no other DTCs or
Output Circuit Short to symptoms are present, INSPECT the SJB and C2280f for bent pins,
Ground loose or corroded connections. If no concerns are found, INSTALL a
new SJB . REFER to Section 419-10 . TEST the system for normal
operation.
B2A2C Right Corner Lamp DIAGNOSE all other DTCs and symptoms first. If no other DTCs or
Output Circuit Short to symptoms are present, INSPECT the SJB and C2280f for bent pins,
Ground loose or corroded connections. If no concerns are found, INSTALL a
new SJB . REFER to Section 419-10 . TEST the system for normal
operation.
B2A2E Right Front Lamp Low If the low beam is inoperative, GO to Pinpoint Test B .
Beam Circuit Open
If the low beam is always on, GO to Pinpoint Test D .
B2A2F Right Front Lamp Low GO to Pinpoint Test B .
Beam Circuit Short to
Ground
B2A30 Left Front Lamp Low If the low beam is inoperative, GO to Pinpoint Test B .
Beam Circuit Open

If the low beam is always on, GO to Pinpoint Test D .

B2A31 Left Front Lamp Low GO to Pinpoint Test B .
Beam Circuit Short to
Ground
All other - REFER to the Diagnostic Trouble Code (DTC) Chart in Section
DTCs 419-10 .
Headlamp Control Module (HCM) DTC Chart

B1A98:88 LIN Bus Circuit #1: Bus off GO to Pinpoint Test AA .
B1D64:01 Left Headlamp Swivelling Motor: INSTALL a new LH headlamp assembly. REFER to
General Electrical Failure Headlamp Assembly in this section. CLEAR the DTCs.
B1D64:87 Left Headlamp Swivelling Motor: GO to Pinpoint Test AB .
Missing Message
B1D65:01 Right Headlamp Swivelling Motor: INSTALL a new RH headlamp assembly. REFER to
General Electrical Failure Headlamp Assembly in this section. CLEAR the DTCs.
B1D65:87 Right Headlamp Swivelling Motor: GO to Pinpoint Test AB .
Missing Message
U0001:88 High Speed CAN Communication REFER to Section 418-00 .
Bus: Bus off
U0100:87 Lost Communication With GO to Pinpoint Test AC .
ECM/PCM "A": Missing Message
U0101:87 Lost Communication With TCM: GO to Pinpoint Test AD .
Missing Message
Anti-Lock Brake System (ABS)
Control Module: Missing Message
U0126:87 Lost Communication With Steering GO to Pinpoint Test AF .
Angle Sensor Module: Missing
Message
U0155:87 Lost Communication with GO to Pinpoint Test AG .
Control Module: Missing Message
U0401:86 Invalid Data Received From DTC U0401:86 is set when a module receives invalid
ECM/PCM A: Signal Invalid network data from another module with a faulted input.
RETRIEVE and REPAIR all non-network DTCs in the PCM
and other modules on the network. REFER to Section
419-10 .
U0402:86

Invalid Data Received from TCM: DTC U0401:86 is set when a module receives invalid
Signal Invalid network data from another module with a faulted input.
RETRIEVE and REPAIR all non-network DTCs in the TCM
and other modules on the network. REFER to Section
419-10 .
Anti-Lock Brake System (ABS) network data from another module with a faulted input.
Control Module: Signal Invalid RETRIEVE and REPAIR all non-network DTCs in the ABS
module and other modules on the network. REFER to
Section 419-10 .
Instrument Panel Control Module: network data from another module with a faulted input.
Signal Invalid RETRIEVE and REPAIR all non-network DTCs in the
Instrument Panel Cluster (IPC) and other modules on the
network. REFER to Section 419-10 .
Steering Angle Sensor Module: network data from another module with a faulted input.
Signal Invalid RETRIEVE and REPAIR all non-network DTCs in the
Power Steering Control Module (PSCM) and other modules
on the network. REFER to Section 419-10 .
U3000:04 Control Module: System Internal INSTALL a new Headlamp Control Module (HCM).
Failure REFER to Headlamp Control Module (HCM) in this section.
U3000:46 Control Module: INSTALL a new Headlamp Control Module (HCM).
Calibration/Parameter Memory REFER to Headlamp Control Module (HCM) in this section.
Failure
U3003:16 Battery Voltage: Circuit Voltage GO to Pinpoint Test AH .
Below Threshold
U3003:17 Battery Voltage: Circuit Voltage GO to Pinpoint Test AI .
Above Threshold
PCM DTC Chart

P1910 Reverse Lamp Control If the reversing lamps are inoperative, GO to Pinpoint Test W
Circuit/Open .
If the reversing lamps are always on, GO to Pinpoint Test Y .

All other - REFER to the Diagnostic Trouble Code (DTC) Chart in
DTCs Section 419-10 .



Manual
Headlamps
Special Tool(s)


Flex Probe Kit
Exterior Lighting
The SJB monitors the headlamp switch position by sending voltage signals on multiple circuits to the
headlamp switch. There is one circuit for each headlamp switch position. At any given time, one of the signal
circuits is switched to ground.
If the SJB does not detect any of the inputs to the headlamp switch is active (switched to ground) for 5
seconds, the SJB turns on the parking lamps and headlamps and keeps them on until the battery saver feature
times out.
Additionally, if the SJB detects multiple headlamp switch input circuits short to ground, the SJB turns the
parking lamps and headlamps on and keeps them on until the battery saver feature times out.
Refer to Exterior Lighting for information regarding the Battery Saver feature.
If either of the above situations occur, the SJB cannot be ruled immediately as being at fault. This is normal
behavior of the SJB design as it has detected a fault with the inputs from the headlamp switch.
The SJB also monitors the multifunction switch for a flash-to-pass or high beam request. There are 2 voltage
signal circuits which monitor this. When the multifunction switch is in the FLASH-TO-PASS or HIGH
BEAM position, the voltage signal is routed to ground.
NOTE: The flash-to-pass feature does not require any input from the headlamp switch.
When the SJB receives an input requesting the headlamps on, the SJB supplies voltage to the low beam and
high beam bulbs as necessary.
Headlamp Functionality
Headlamps 5971
Vehicles equipped with High Intensity Discharge (HID) headlamps utilize a relay to provide voltage to the
ballasts. When the HID relays are energized, the ballasts provide the required high voltage to illuminate the
HID bulbs.
When the high beams are requested, the high beams are illuminated and the low beams turn off.
When the flash-to-pass feature is requested, the high beams are illuminated as long as the multifunction
The SJB FET protected output circuits for the headlamps are the LH and RH low beam output circuits.
Headlamps 5972
2. Visually inspect the following for obvious signs of mechanical or electrical damage.
• Headlamp • Battery Junction Box (BJB)
switch fuse(s):
• Multifunction ♦ 26 (15A) (LH
switch ballast)
• Headlamp ♦ 27 (15A) (RH
assembly ballast)
fuse(s):
♦ 7 (10A) (LH low
beam)
♦ 8 (10A) (RH low
beam)
♦ 23 (15A) (high
beams)
• Bulb(s)
• Headlamp relay
connectors
• SJB



418-00 .
Headlamps 5973
9. If the DTCs retrieved are related to the concern, go to Diagnostic Trouble Code (DTC) Chart in this
section. For all other DTCs, refer to the Diagnostic Trouble Code (DTC) Chart in Section 419-10 .
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: Both High Beams Are Inoperative
Refer to Wiring Diagrams Cell 85 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Headlamps/Autolamps for
Normal Operation
When the headlamp switch is placed in the HEADLAMPS ON position, the Smart Junction Box (SJB)
monitors the high beam request circuit from the multifunction switch. When the multifunction switch is
placed in the HIGH BEAM position, the signal is switched to ground, indicating a request for the high beams.
The SJB then energizes the high beam relay (integrated into the SJB ) which supplies voltage to the
headlamps.
The SJB communicates to the Instrument Panel Cluster (IPC) (over the communication network) to illuminate
the high beam indicator.
• Fuse
• SJB
PINPOINT TEST A: BOTH HIGH BEAMS ARE INOPERATIVE

A1 CHECK THE HIGH BEAM INDICATOR
Yes
• Ignition OFF. VERIFY the SJB fuse 23 (15A) is OK. If
• Place the headlamp switch in the HEADLAMPS OK, GO to A5 . If not OK, REFER to the
ON position. Wiring Diagrams Manual to identify the
• Place the multifunction switch in the HIGH BEAM possible causes of the circuit short.
position.

• Does the high beam indicator illuminate? No

GO to A2 .
A2 BYPASS THE MULTIFUNCTION SWITCH
Yes
• Place the headlamp switch in the OFF position. REMOVE the jumper wire. INSTALL a
• Disconnect: Multifunction Switch C202. new multifunction switch. REFER to
• Place the headlamp switch in the HEADLAMPS Section 211-05 . TEST the system for
ON position. normal operation.
• Connect a fused jumper wire between the
multifunction switch C202-6, circuit CLF17 No
(WH/OG), harness side and the multifunction switch REMOVE the jumper wire. GO to A3 .
C202-8, circuit GD116 (BK/VT), harness side.
• Do the high beams illuminate?

A3 CHECK FOR VOLTAGE TO THE
MULTIFUNCTION SWITCH
Yes
• Measure the voltage between the multifunction REPAIR circuit GD116 (BK/VT) for an
switch C202-6, circuit CLF17 (WH/OG), harness open. TEST the system for normal
side and ground. operation.
No
GO to A4 .

A4 CHECK THE HIGH BEAM REQUEST INPUT
CIRCUIT FOR AN OPEN
Yes
• Disconnect: SJB C2280b. GO to A6 .
• Measure the resistance between the multifunction
switch C202-6, circuit CLF17 (WH/OG), harness No
side and the SJB C2280b-27, circuit CLF17 REPAIR circuit CLF17 (WH/OG) for an
(WH/OG), harness side. open. TEST the system for normal
operation.
PINPOINT TEST A: BOTH HIGH BEAMS ARE INOPERATIVE 5975


A5 CHECK THE SJB HIGH BEAM OUTPUT
CIRCUIT FOR AN OPEN
Yes
• Place the headlamp switch in the OFF position. REMOVE the jumper wire. GO to A6 .
• Disconnect: SJB C2280e.
• Connect a fused jumper wire between the SJB No
C2280e-1, circuit CDC34 (WH/OG), harness side REMOVE the jumper wire. REPAIR
and the SJB C2280e-2, circuit CLF08 (YE/VT), circuit CLF08 (YE/VT) for an open. TEST
harness side. the system for normal operation.
• Ignition ON.
Yes
• Disconnect all the SJB connectors. INSTALL a new SJB . REFER to Section
• Check for: 419-10 . TEST the system for normal
♦ damaged pins
• Connect all the SJB connectors and make sure they The system is operating correctly at this
present.
Pinpoint Test B: One Low Beam Headlamp Is Inoperative
Normal Operation - Fusion and MKZ With Halogen Headlamps
When the Smart Junction Box (SJB) detects the headlamp switch in the HEADLAMPS ON position and the
multifunction switch in the LOW BEAM position, the SJB provides voltage to the LH and RH low beam
headlamps.
Normal Operation - Fusion and MKZ With Halogen Headlamps 5976

MKZ with High Intensity Discharge (HID) Headlamps
When the Smart Junction Box (SJB) detects the headlamp switch in the HEADLAMPS ON position and the
multifunction switch in the LOW BEAM position, the SJB provides voltage to the LH and RH headlamp
relays. When the headlamp relays are energized, voltage is switched to the headlamps.
For MKZ with HID headlamps, the ballasts then provide the required high voltage to illuminate the HID
headlamp bulbs.

• B106E - Solid driver. The module has temporarily disabled a low beam output because an
State Driver excessive current draw exists (such as a short to ground). T SJB cannot enable
Disabled Due the low beam output until the cause of the short is corrected, the DTCs have
to Short been cleared and a successful self-test is run.
Circuit
A continuous DTC that sets when the SJB has permanently shut down the output
• B106F - driver. The module has permanently disabled a low beam output because an
Module excessive current draw fault (such as a short to ground) has exceeded the limits
Disabled Due that the SJB can withstand. The cause of the excessive current draw MUST be
to External corrected before a new SJB is installed.
Fault
An on-demand DTC that sets when the SJB detects an open from the RH low beam
• B2A2E - output circuit.
Right Front
Lamp Low
Beam Circuit
Open
• B2A2F - Right from the beam output circuit.
Front Lamp
Low Beam
Circuit Short
to Ground
An on-demand DTC that sets when the SJB detects an open from the LH low beam
• B2A30 - Left output circuit.
Front Lamp
Low Beam
Circuit Open
• B2A31 - Left from the LH low beam output circuit.
Front Lamp
Low Beam
Circuit Short
to Ground
• Fuse
MKZ with High Intensity Discharge (HID) Headlamps 5977

• Headlamp relay
• Ballast
• Bulb
• Headlamp assembly
• SJB
PINPOINT TEST B: ONE LOW BEAM HEADLAMP IS INOPERATIVE
NOTE: Due to varying wattage ratings and resulting current draw of certain aftermarket headlamp bulbs, the
SJB may activate its short circuit protection strategy, resulting in the low beam output circuit(s) becoming
inoperative. Verify that the bulbs meet Ford specifications. If the bulbs do not meet Ford specifications, install
the correct bulbs. Clear the DTCs and rhe on-demand self-test (required to reset the SJB ). Correct any
unresolved DTCs. Test the system for normal operation.

B1 CHECK FOR VOLTAGE TO THE HEADLAMP
Yes
• Disconnect: Inoperative Headlamp.
• Place the headlamp switch in the HEADLAMPS No
ON position. For MKZ with halogen headlamps or Fusion,
• For Fusion or MKZ with halogen headlamps, GO to B5 . For MKZ with HID headlamps,
measure the voltage between the LH headlamp GO to B10 .
C1021-6, circuit CLF04 (BN/BU), harness side
and ground; or between the RH headlamp
C1041-6, circuit CLF05 (BU/GN), harness side
and ground.
• For MKZ with HID headlamps, measure the

voltage between the LH headlamp C1021-6,
circuit CLF30 (VT/BN), harness side and ground;
or between the RH headlamp C1041-6, circuit
CLF31 (YE/GY), harness side and ground.
PINPOINT TEST B: ONE LOW BEAM HEADLAMP IS INOPERATIVE 5978


B2 CHECK FOR VOLTAGE TO THE HEADLAMP
USING THE CONNECTOR GROUND
Yes
• For Fusion or MKZ with halogen headlamps, For MKZ with HID headlamps, GO to B3 .
measure the voltage between the LH headlamp
C1021-6, circuit CLF04 (BN/BU), harness side For all others, REPAIR or INSTALL a new
and the LH headlamp C1021-1, circuit GD121 headlamp assembly. REFER to Headlamp
(BK/YE), harness side; or between the RH Assembly in this section. TEST the system
headlamp C1041-6, circuit CLF05 (BU/GN), for normal operation.
harness side and the RH headlamp C1041-1,
circuit GD123 (BK/GY), harness side. No
REPAIR circuit GD121 (BK/YE) (LH
headlamp) or circuit GD123 (BK/GY) for an
open. TEST the system for normal operation.
• For MKZ with HID headlamps, measure the

voltage between the LH headlamp C1021-6,
circuit CLF30 (VT/BN), harness side and the LH
headlamp C1021-1, circuit GD121 (BK/YE),
harness side; or between the RH headlamp
C1041-6, circuit CLF31 (YE/GY), harness side
and the RH headlamp C1041-1, circuit GD123
(BK/GY), harness side.

B3 SUBSTITUTE THE HID BULB
Yes
• Place the headlamp switch in the OFF position. INSTALL a new HID headlamp bulb.
• Substitute a known good HID bulb. REFER to Headlamp Bulb - LH, MKZ or
• Place the headlamp switch in the HEADLAMPS Headlamp Bulb - RH, MKZ in this section.
ON position. TEST the system for normal operation.
• Does the headlamp illuminate?

No
REINSTALL the HID bulb. GO to B4 .
B4 SUBSTITUTE THE BALLAST
Yes
• Place the headlamp switch in the OFF position. INSTALL a new ballast. REFER to Ballast
• Substitute a known good ballast. in this section. TEST the system for normal
• Place the headlamp switch in the HEADLAMPS operation.
ON position.
• Does the headlamp illuminate? No
INSTALL a new headlamp assembly.
REFER to Headlamp Assembly in this
operation.
B5 USE THE RECORDED DTCs FROM THE SJB
SELF-TEST
Yes
• Place the headlamp switch in the OFF position. GO to B6 .
• Check the recorded results from the SJB self-test.
• Is DTC B2A2E or DTC B2A30 present? No
VERIFY the SJB fuse 7 (10A) (LH low
beam) or fuse 8 (10A) (RH low beam) is OK.
If OK, GO to B7 . If not OK, REFER to the
Wiring Diagrams Manual to identify the
possible causes of the circuit short. After the
repair: If no DTCs are present, TEST the
system for normal operation. If DTC B106E
is present, CLEAR the DTCs and REPEAT
the self-test (required to enable the low
beam output driver if DTC B106E is
operation. If DTC B106F is present,
operation.
B6 CHECK THE SJB HEADLAMP VOLTAGE
SUPPLY CIRCUIT FOR AN OPEN (FUSION OR
MKZ WITH HALOGEN HEADLAMPS)
Yes
• Disconnect: SJB C2280e. GO to B21 .
• Measure the resistance between the LH headlamp
C1021-6, circuit CLF04 (BN/BU), harness side No
and the SJB C2280e-13, circuit CLF04 (BN/BU), REPAIR circuit CLF04 (BN/BU) (LH
harness side; or between the RH headlamp headlamp) or circuit CLF05 (BU/GN) (RH
C1041-6, circuit CLF05 (BU/GN), harness side headlamp) for an open. CLEAR the DTCs.
and the SJB C2280e-4, circuit CLF05 (BU/GN), REPEAT the self-test.
harness side.


B7 ISOLATE THE HEADLAMP AS THE CAUSE
OF THE SHORT
Yes
tool: SJB Self-Test. No
• Clear the DTCs and repeat the on-demand GO to B8 .
self-test (required to enable the low beam
output driver if DTC B106E is present) .
• Place the headlamp switch in the HEADLAMPS
ON position.
• Measure the voltage between the LH headlamp
C1021-6, circuit CLF04 (BN/BU), harness side
C1041-6, circuit CLF05 (BU/GN), harness side
and ground.

B8 CHECK THE SJB LOW BEAM OUTPUT
CIRCUIT FOR A SHORT TO GROUND (FUSION
OR MKZ WITH HALOGEN HEADLAMPS)
Yes
• Measure the resistance between the LH headlamp No
C1021-6, circuit CLF04 (BN/BU), harness side REPAIR circuit CLF04 (BN/BU) (LH low
and ground; or between the RH headlamp beam) or circuit CLF05 (BU/GN) (RH low
C1041-6, circuit CLF05 (BU/GN), harness side beam) for a short to ground. After the repair:
and ground. If no DTCs are present, TEST the system for
normal operation. If DTC B106E is present,
CLEAR the DTCs and REPEAT the self-test
(required to enable the low beam output
driver if DTC B106E is present) . TEST the
system for normal operation. If DTC B106F
is present, INSTALL a new SJB . REFER to
Section 419-10 . TEST the system for normal
operation.


B9 ISOLATE THE HEADLAMP AS THE CAUSE
OF THE SHORT (FUSION OR MKZ WITH HID
HEADLAMPS)
Yes
• Ignition ON. INSTALL a new headlamp assembly.
• Disconnect: Headlamp Bulb. REFER to Headlamp Assembly in this
• Connect: Headlamp Assembly. section. After the repair: If no DTCs are
• Ignition ON. present, TEST the system for normal
• Enter the following diagnostic mode on the scan operation. If DTC B106E is present, CLEAR
tool: SJB Self-Test. the DTCs and REPEAT the self-test
• Clear the DTCs and repeat the on-demand (required to enable the low beam output
self-test. driver if DTC B106E is present) . TEST the
• Is DTC B2A31 (LH headlamp) or DTC B2A2F system for normal operation. If DTC B106F
(RH headlamp) present? is present, INSTALL a new SJB . REFER to
operation.
No
INSTALL a new headlamp bulb. REFER to
Headlamp Bulb - LH, Fusion or Headlamp
Bulb - RH, Fusion in this section. After the
repair: If no DTCs are present, TEST the
system for normal operation. If DTC B106E
is present, CLEAR the DTCs and REPEAT
the self-test (required to enable the low
beam output driver if DTC B106E is
operation. If DTC B106F is present,
operation.
B10 CHECK THE HEADLAMP RELAY
Yes
• Place the headlamp switch in the OFF position. REMOVE the known good relay. INSTALL
• Disconnect: Suspect Headlamp Relay. a new headlamp relay. TEST the system for
• Substitute a known good relay. normal operation.
• Ignition ON.
tool: SJB Self-Test. For MKZ non-Hybrid, REMOVE the known
• Clear the DTCs and repeat the on-demand good relay. GO to B11 . For MKZ Hybrid,
self-test (required to enable the low beam REMOVE the known good relay. GO to B16
output driver if DTC B106E is present) . .
• Place the headlamp switch in the HEADLAMPS
ON position.
• Measure the voltage between the LH headlamp
C1021-6, circuit CLF30 (VT/BN), harness side


C1041-6, circuit CLF31 (YE/GY), harness side
and ground.

B11 CHECK FOR VOLTAGE TO THE
HEADLAMP RELAY
Yes
• Ignition OFF.
• For the LH headlamp, measure the voltage No
between the LH headlamp relay pin 3, circuit VERIFY the BJB fuse 26 (15A) (LH
SBB26 (YE/RD), BJB face side and ground. headlamp) or fuse 27 (15A) (RH headlamp)
is OK. If OK, REPAIR circuit SBB26
(YE/RD) (LH headlamp) or circuit SBB27
(BU/RD) (RH headlamp) for an open. TEST
the system for normal operation. If not OK,
short.
• For the RH headlamp, measure the voltage

between the RH headlamp relay pin 3, circuit
SBB27 (BU/RD), BJB face side and ground.

HEADLAMP RELAY USING THE RELAY
GROUND

• For the LH headlamp, measure the voltage Yes

between the LH headlamp relay pin 3, circuit GO to B13 .
SBB26 (YE/RD), BJB face side and the LH
headlamp relay pin 2, circuit GD121 (BK/YE), No
BJB face side. REPAIR circuit GD121 (BK/YE) for an
open. TEST the system for normal operation

SBB27 (BU/RD), BJB face side and the RH
headlamp relay pin 2, circuit GD121 (BK/YE),
BJB face side.

B13 BYPASS THE HEADLAMP RELAY
Yes
• Connect: Headlamp Assembly. REMOVE the jumper wire. GO to B14 .
• For the LH headlamp, connect a fused jumper
wire between the LH headlamp relay pin 3, circuit No
SBB26 (YE/RD), BJB face side and the LH REMOVE the jumper wire. REPAIR circuit
headlamp relay pin 5, circuit CLF30 (VT/BN), CLF30 (VT/BN) (LH headlamp) or circuit
BJB face side. CLF31 (YE/GY) (RH headlamp) for an open.
• For the RH headlamp, connect a fused jumper

wire between the RH headlamp relay pin 3, circuit
headlamp relay pin 5, circuit CLF31 (YE/GY),
BJB face side.


CIRCUIT FOR A SHORT TO GROUND (MKZ
NON-HYBRID HID HEADLAMPS)
Yes
• For the LH headlamp, measure the resistance
between the LH headlamp relay pin 1, circuit No
CLF04 (BN/BU), BJB face side and ground. REPAIR circuit CLF04 (BN/BU) (LH low
beam) or circuit CLF05 (BU/GN) (RH low
beam) for a short to ground. After the repair:
If no DTCs are present, TEST the system for
normal operation. If DTC B106E is present,
• For the RH headlamp, measure the resistance
operation.
CLF05 (BU/GN), BJB face side and ground.

SUPPLY CIRCUIT FOR AN OPEN (MKZ
NON-HYBRID HID HEADLAMPS)
Yes
• For the LH headlamp, measure the resistance GO to B21 .
between the LH headlamp relay pin 1, circuit
CLF04 (BN/BU), BJB face side and the SJB No
C2280e-13, circuit CLF04 (BN/BU), harness side. REPAIR circuit CLF04 (BN/BU) (LH
headlamp) or circuit CLF05 (BU/GN) (RH
headlamp) for an open. TEST the system for
normal operation.

• For the RH headlamp, measure the resistance

CLF05 (BU/GN), BJB face side and the SJB
C2280e-4, circuit CLF05 (BU/GN), harness side.

HEADLAMP RELAY (MKZ HYBRID)
Yes
• Ignition OFF.
• For the LH headlamp, measure the voltage No
between the LH headlamp relay pin 3, circuit VERIFY the BJB fuse 26 (15A) (LH
SBB26 (YE/RD), BJB face side and ground. headlamp) or fuse 27 (15A) (RH headlamp)
• For the RH headlamp, measure the voltage is OK. If OK, REPAIR circuit SBB26
between the RH headlamp relay pin 3, circuit (YE/RD) (LH headlamp) or circuit SBB27
SBB27 (BU/RD), BJB face side and ground. (BU/RD) (RH headlamp) for an open. TEST
• Is the voltage greater than 10 volts? the system for normal operation. If not OK,
short.
HEADLAMP RELAY USING THE RELAY
GROUND (MKZ HYBRID)
Yes
• For the LH headlamp, measure the voltage GO to B18 .
between the LH headlamp relay pin 3, circuit
SBB26 (YE/RD), BJB face side and the LH No
headlamp relay pin 1, circuit GD123 (BK/GY), REPAIR circuit GD121 (BK/YE) for an
BJB face side. open. TEST the system for normal operation
headlamp relay pin 1 circuit GD123 (BK/GY)
BJB face side.
B18 BYPASS THE HEADLAMP RELAY (MKZ
HYBRID)

• Connect: Headlamp Assembly. Yes

• For the LH headlamp, connect a fused jumper REMOVE the jumper wire. GO to B19 .
wire between the LH headlamp relay pin 3, circuit
SBB26 (YE/RD), BJB face side and the LH No
headlamp relay pin 5, circuit CLF30 (VT/BN), REMOVE the jumper wire. REPAIR circuit
BJB face side. CLF30 (VT/BN) (LH headlamp) or circuit
• For the RH headlamp, connect a fused jumper CLF31 (YE/GY) (RH headlamp) for an open.
wire between the RH headlamp relay pin 3, circuit TEST the system for normal operation.
headlamp relay pin 5, circuit CLF31 (YE/GY),
BJB face side.
CIRCUIT FOR A SHORT TO GROUND (MKZ
HYBRID)
Yes
• For the LH headlamp, measure the resistance
between the LH headlamp relay pin 2 circuit No
CLF04 (BN/BU), BJB face side and ground. REPAIR circuit CLF04 (BN/BU) (LH low
• For the RH headlamp, measure the resistance beam) or circuit CLF05 (BU/GN) (RH low
between the RH headlamp relay pin 2 circuit beam) for a short to ground. After the repair:
CLF05 (BU/GN), BJB face side and ground. If no DTCs are present, TEST the system for
• Is the resistance greater than 10,000 ohms? normal operation. If DTC B106E is present,
operation.
SUPPLY CIRCUIT FOR AN OPEN (MKZ HYBRID)
Yes
• For the LH headlamp, measure the resistance GO to B16 .
between the LH headlamp relay pin 2 circuit
CLF04 (BN/BU), BJB face side and the SJB No
C2280e-13, circuit CLF04 (BN/BU), harness side. REPAIR circuit CLF04 (BN/BU) (LH
• For the RH headlamp, measure the resistance headlamp) or circuit CLF05 (BU/GN) (RH
between the RH headlamp relay pin 2 circuit headlamp) for an open. TEST the system for
CLF05 (BU/GN), BJB face side and the SJB normal operation.
C2280e-4, circuit CLF05 (BU/GN), harness side.
Yes
♦ damaged pins
• Connect all the SJB connectors and make sure The system is operating correctly at this time.
they seat correctly. The concern may have been caused by a
loose or corroded connector.


present.
Pinpoint Test C: One High Beam Headlamp Is Inoperative
Normal Operation
When low beams are on and the Smart Junction Box (SJB) detects the multifunction switch in the HIGH
BEAM position, the SJB energizes an internal relay. When the relay is energized, the relay routes voltage to
the headlamps.

PINPOINT TEST C: ONE HIGH BEAM HEADLAMP IS INOPERATIVE

C1 CHECK FOR VOLTAGE TO THE HEADLAMP
Yes
• Disconnect: Inoperative Headlamp.
• Place the headlamp switch in the HEADLAMPS ON position. No
• Place the multifunction switch in the HIGH BEAM position. REPAIR circuit CLF08
• Measure the voltage between the LH headlamp C1021-7, circuit (YE/VT) for an open. TEST
CLF08 (YE/VT), harness side and ground; or between the RH the system for normal
headlamp C1041-7, circuit CLF08 (YE/VT), harness side and operation.
ground.

C2 CHECK FOR VOLTAGE TO THE HEADLAMP USING THE
HIGH BEAM GROUND PIN

• Measure the voltage between the LH headlamp C1021-7, circuit Yes

CLF08 (YE/VT), harness side and the LH headlamp C1021-4, REPAIR or INSTALL a new
circuit GD121 (BK/YE), harness side; or between the RH headlamp assembly. REFER to
headlamp C1041-7, circuit CLF08 (YE/VT), harness side and Headlamp Assembly in this
the RH headlamp C1041-4, circuit GD123 (BK/GY), harness section. TEST the system for
side. normal operation.
No
(BK/YE) (LH headlamp) or
circuit GD123 (BK/GY) (RH
headlamp) for an open. TEST
operation.
Pinpoint Test D: The Low Beam(s) Are Always On
Normal Operation
The Smart Junction Box (SJB) sends voltage signals to the headlamp switch through individual circuits (OFF,
PARKING LAMPS and HEADLAMPS). At any given time, the headlamp switch routes one of the input
circuits to ground.
When the SJB detects the headlamp switch in the HEADLAMPS ON position (or a fault with one of the
headlamp switch input circuits for more than 5 seconds) and the multifunction switch in the LOW BEAM
position, the SJB provides voltage to the headlamps.
For MKZ equipped with High Intensity Discharge (HID) headlamps, a relay is utilized to provide voltage for
the low beam headlamps.

An on-demand DTC that may set when the SJB detects the headlamps
• B1472 - Lamp Headlamp on input circuit is short to ground.
Input Circuit Short to Ground
An on-demand DTC that may set when the SJB detects multiple
• B2498 - Headlamp Switch headlamp switch inputs active at the same time.
Multiple Signals Input Active
An on-demand DTC that sets when the SJB detects the headlamp
• B2A22 - Headlamp OFF switch off input circuit open.
Circuit Open
An on-demand DTC that sets when the SJB detects the RH low beam
• B2A2E - Right Front Lamp output circuit shorted to voltage.
Low Beam Circuit Open
PINPOINT TEST C: ONE HIGH BEAM HEADLAMP IS INOPERATIVE 5989

• B2A30 - Left Front Lamp An on-demand DTC that sets when the SJB detects the LH low beam
Low Beam Circuit Open output circuit shorted to volta

• Headlamp relay
• Headlamp switch
• SJB
PINPOINT TEST D: THE LOW BEAM(S) ARE ALWAYS ON

D1 CHECK FOR AUTOLAMP DTCs
Yes
• Review the DTCs retrieved from the SJB self-test. REFER to Autolamps in this section.
• Is DTC B1696, B1791, B1793 or B2008 present?
No
If equipped with autolamps, GO to D2 . If
not equipped with autolamps, GO to D3 .
D2 CHECK THE SJB AUTOLAMP ON REQUEST
PID
Yes
• While placing the headlamp switch in the GO to Pinpoint Test H .
AUTOLAMPS ON and then OFF position, monitor
the SJB headlamp switch PID
(HDLMP_AUT_CKT).
• Does the PID indicate ON with the headlamp
switch in the AUTOLAMPS ON position and
OFF when the headlamp switch is in the OFF
position?
D3 CHECK THE SJB HEADLAMP SWITCH PIDs
Yes
NOTE: Make sure the headlamp switch is lined up GO to D8 .
in the correct position when monitoring the PIDs.
No
• Enter the following diagnostic mode on the scan GO to D4 .
tool: SJB DataLogger.
• NOTE: Only one PID should indicate ON at each
headlamp switch position.
• While moving the headlamp switch through all
positions, monitor the SJB headlamp switch input
PIDs (HDLMP_OFF_CKT, HDLMP_PRK_CKT,
HDLMP_ON_CKT).

• Do the headlamp switch positions agree with the

PIDs (with only one PID indicating ON in each
position)?
D4 CHECK FOR VOLTAGE SIGNALS TO THE
HEADLAMP SWITCH
Yes
• Disconnect: Headlamp Switch C205.
• Measure the voltage between the headlamp switch, No
harness side and ground as follows: GO to D6 .
Headlamp Switch Connector-Pin Circuit

C205-6 CLF23
(WH/VT)
C205-2 CLS34 (GY)
C205-7 CLF18
(BU/WH)

D5 CHECK FOR VOLTAGE TO THE HEADLAMP
SWITCH USING THE CONNECTOR GROUND
Yes
• Measure the voltage between the headlamp switch INSTALL a new headlamp switch. REFER
C205-6, circuit CLF23 (WH/VT), harness side and to Headlamp Switch in this section. TEST
the headlamp switch C205-3, circuit GD116 the system for normal operation.
(BK/VT), harness side.
No
operation.

D6 CHECK THE HEADLAMP SWITCH INPUT
PINPOINT TEST D: THE LOW BEAM(S) ARE ALWAYS ON 5991

• Disconnect: SJB C2280b. Yes

• Measure the resistance between the headlamp GO to D7 .
switch, harness side and ground as follows:
No
REPAIR the circuit in question for a short
to ground. TEST the system for normal
operation.
Headlamp Switch Connector-Pin Circuit
C205-6 CLF23
(WH/VT)
C205-2 CLS34 (GY)
C205-7 CLF18
(BU/WH)

D7 CHECK THE HEADLAMP SWITCH INPUT
Yes
• Measure the resistance between the headlamp GO to D11 .
switch, harness side and the SJB , harness side as
follows: No
REPAIR the circuit in question for an open.
Headlamp Switch SJB

Connector-Pin Connector-Pin Circuit
C205-6 C2280b-47 CLF23
(WH/VT)
C205-2 C2280b-31 CLF34
(YE/OG)
C205-7 C2280b-30 CLF18
(BU/WH)

D8 CHECK THE SJB OUTPUT

Yes
• Disconnect: SJB C2280e. For MKZ with halogen headlamps or
• Does the LH or RH headlamp continue to Fusion, REPAIR circuit CLF04 (BN/BU)
illuminate? (LH headlamp) or circuit CLF05 (BU/GN)
(RH headlamp) for a short to voltage.
TEST the system for normal operation. For
MKZ with HID headlamps, GO to D9 .
No
GO to D11 .
D9 CHECK THE HEADLAMP RELAY OUTPUT
Yes
• Disconnect: Suspect Headlamp Relay. REPAIR circuit CLF30 (VT/BN) (LH
• Does the LH or RH headlamp continue to headlamp) or circuit CLF31 (YE/GY) (RH
illuminate? headlamp) for a short to voltage. TEST the
No
GO to D10 .
D10 CHECK HEADLAMP RELAY
Yes
• Substitute a known good relay. REPAIR circuit CLF04 (BN/BU) (LH
• Does the LH or RH headlamp continue to headlamp) or circuit CLF05 (BU/GN) (RH
illuminate? headlamp) for a short to voltage. TEST the
No
REMOVE the known good relay.
INSTALL a new headlamp relay. TEST the
D11 CHECK FOR CORRECT SJB OPERATION
Yes
♦ damaged pins
present.
Pinpoint Test E: The High Beam(s) Are Always On

Normal Operation
The Smart Junction Box (SJB) sends a voltage signal to the multifunction switch for the high beam and
flash-to-pass requests. When the multifunction switch is placed in the FLASH-TO-PASS or HIGH BEAM
position, the voltage signal is routed to ground. When the SJB detects a request for flash-to-pass or high
beams (when the low beams are on), the SJB energizes the high beam relay (integrated into the SJB ), which
routes voltage to the headlamps.
• DTC B1510 (Flash To Pass Switch Circuit Short to Ground) - an on-demand DTC that sets when the
SJB detects the flash-to-pass request input circuit is short to ground.
• DTC B2A23 (High Beam Input Circuit Short to Ground) - an on-demand DTC that sets when the SJB
detects a short to ground on the high beam request input circuit.

• SJB
PINPOINT TEST E: THE HIGH BEAM(S) ARE ALWAYS ON

E1 CHECK FOR DTC B1510 OR DTC B2A23
Yes
• Review the DTCs retrieved from the SJB self-test. GO to E2 .
• Is DTC B1510 or DTC B2A23 present?
No
For Fusion or MKZ, GO to E4 .
E2 CHECK THE MULTIFUNCTION SWITCH
Yes
• Disconnect: Multifunction Switch C202.
• Ignition ON. No
• Do the high beams continue to illuminate? INSTALL a new multifunction switch.
REFER to Section 211-05 . CLEAR the
E3 CHECK THE HIGH BEAM AND FLASH-TO-PASS
REQUEST INPUT CIRCUITS FOR A SHORT TO
GROUND
Yes
• Measure the resistance between the multifunction No
switch C202-6, circuit CLF17 (WH/OG), harness side REPAIR the circuit in question for a
and ground; and between the multifunction switch short to ground. CLEAR the DTCs.
C202-4, circuit CLF27 (GN/BN), harness side and REPEAT the self-test.
ground.


E4 CHECK THE SJB HIGH BEAM OUTPUT CIRCUIT
FOR A SHORT TO VOLTAGE (FUSION OR MKZ)
Yes
• Ignition OFF. REPAIR circuit CLF08 (YE/VT) for a
• Disconnect: SJB C2280e. short to voltage. TEST the system for
• Ignition ON. normal operation.
• Do the high beams continue to illuminate?
No
GO to E5 .
E5 CHECK FOR CORRECT SJB OPERATION
Yes
♦ damaged pins
seat correctly. time. The concern may have been
• Is the concern still present? self-test.
Pinpoint Test F: The Flash-To-Pass Feature Is Inoperative
Normal Operation
The Smart Junction Box (SJB) sends a voltage signal to the multifunction switch for the flash-to-pass request.
When the multifunction switch is placed in the FLASH-TO-PASS position, the voltage signal is routed to
ground. When the SJB detects a request for the flash-to-pass, the SJB provides voltage to the high beam
headlamps.

• SJB
PINPOINT TEST E: THE HIGH BEAM(S) ARE ALWAYS ON 5995

PINPOINT TEST F: THE FLASH-TO-PASS FEATURE IS INOPERATIVE

F1 VERIFY THE HIGH BEAM HEADLAMP
OPERATION
Yes
• Place the headlamp switch in the HEADLAMPS ON
position. No
• Place the multifunction switch in the HIGH BEAM GO to Pinpoint Test A .
position while observing the headlamps.
• Do the high beam headlamps illuminate?
F2 CHECK THE MULTIFUNCTION SWITCH
Yes
• Ignition OFF. REMOVE the jumper wire. INSTALL a
• Connect a fused jumper wire between the multifunction Section 211-05 . TEST the system for
switch C202-4, circuit CLF27 (GN/BN), harness side normal operation.
and the multifunction switch C202-8, circuit GD116
(BK/VT), harness side. No
REMOVE the jumper wire. GO to F3 .

F3 CHECK THE FLASH-TO-PASS REQUEST INPUT
CIRCUIT FOR AN OPEN
Yes
• Disconnect: SJB C2280b. GO to F4 .
• Measure the resistance between the multifunction
switch C202-4, circuit CLF27 (GN/BN), harness side No
and the SJB C2280b-43, circuit CLF27 (GN/BN), REPAIR circuit CLF27 (GN/BN) for an
harness side. open. TEST the system for normal
operation.

PINPOINT TEST F: THE FLASH-TO-PASS FEATURE IS INOPERATIVE 5996

• Disconnect all the SJB connectors. Yes

• Check for: INSTALL a new SJB . REFER to
♦ corrosion Section 419-10 . TEST the system for
♦ pushed-out pins
• Connect all the SJB connectors and make sure they seat No
• Operate the system and verify the concern is still time. The concern may have been
PINPOINT TEST F: THE FLASH-TO-PASS FEATURE IS INOPERATIVE 5997


Manual
Autolamps
Special Tool(s)


Flex Probe Kit
Exterior Lighting
times out.
Autolamps Feature
The SJB monitors the light sensor with a voltage reference signal. The light sensor input to the SJB varies
with the ambient light conditions.
When the SJB receives an input from the headlamp switch indicating a request for the autolamps, the SJB
monitors the light sensor for the ambient light condition. If the SJB determines the ambient light level is dark,
the SJB supplies voltage to the exterior lamps.
Autolamps 5998
If the ignition switch is already in the RUN position and the vehicle enters a dark/lighted area (such as when
entering/exiting a non-lighted tunnel during the daytime), the transition from light to dark (or dark to light)
needs to last 15 seconds before the SJB turns the exterior lamps on or off. This strategy is to prevent the
exterior lamps from unnecessarily flashing on and off.
The SJB reacts quicker under extreme changes of ambient light conditions. If the SJB has detected a very dark
condition, the exterior lamps are turned on after 1.5 seconds. If the SJB has detected a very high ambient light
level, the exterior lamps are turned off after 4 seconds.
Headlamps On With Wipers On Feature
If the headlamp switch is in the AUTOLAMPS ON position and the front wipers are on for more than 10
seconds (except during a mist wipe or while the wipers are on to clear washer fluid during a wash condition),
the exterior lamps turn on. The exterior lamps turn off when the ignition switch is changed to the OFF or ACC
position, the headlamp switch is placed in the OFF position, or the front wipers are off for more than 30
seconds. The exception to this is when the exterior lights are on because of darkness determined by the light
sensor.
For diagnostics regarding the headlamps on with wipers on feature, refer to Section 501-16 .
• Headlamp • Wiring, terminals
switch or connectors
• Light sensor
• Smart Junction
Box (SJB)

Autolamps 5999


418-00 .
9. If the DTCs retrieved are related to the concern, refer to Diagnostic Trouble Code (DTC) Chart in this
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test G: The Autolamps Are Inoperative
Normal Operation
When the Smart Junction Box (SJB) detects the headlamp switch in the AUTOLAMPS ON position, the SJB
monitors the light sensor input. The light sensor determines the amount of light based on the input received
from the ambient lighting conditions. When the ambient level has reached a point (determined by the internal
programming of the SJB ), the SJB provides voltage to the headlamps, parking and license plate lamps.
• Light sensor
• SJB
PINPOINT TEST G: THE AUTOLAMPS ARE INOPERATIVE

G1 CHECK THE MANUAL HEADLAMP OPERATION

• Place the headlamp switch in the HEADLAMPS ON Yes

position. GO to G2 .
• Do the headlamps and parking lamps operate
correctly? No
REFER to Headlamps or Parking, Rear
and License Plate Lamps in this section.
G2 CHECK FOR VOLTAGE TO THE LIGHT SENSOR
Yes
• Ignition OFF. INSTALL a new light sensor. REFER
• Disconnect: Light Sensor C286 or C287. to Light Sensor in this section. TEST
• Place the headlamp switch in the AUTOLAMPS ON
position. No
• For vehicles with automatic temperature control, GO to G3 .
measure the voltage between the light sensor C286-2,
circuit VLF14 (BU/BN), harness side and ground.
• For vehicles with manual temperature control, measure

the voltage between the light sensor C287-A, circuit
VLF14 (BU/BN), harness side and ground.

G3 CHECK FOR CORRECT SJB OPERATION
Yes
♦ damaged pins
• Connect all the SJB connectors and make sure they seat The system is operating correctly at this
present. connector.
PINPOINT TEST G: THE AUTOLAMPS ARE INOPERATIVE 6001

Pinpoint Test H: The Autolamps Are On Continuously
Normal Operation
The Smart Junction Box (SJB) sends a voltage signal to the headlamp switch to monitor the request for
autolamps and a voltage signal to the light sensor to determine the ambient light level.
When the headlamp switch is placed in the AUTOLAMPS ON position, the voltage signal is routed to
ground. When the SJB detects the headlamp switch in the AUTOLAMPS ON position, the SJB monitors the
light sensor input. The light sensor determines the amount of light based on the input received from the
ambient lighting conditions. When the ambient level has reached a point (determined by the internal
programming of the SJB ), the SJB provides voltage to the headlamps, parking and license plate lamps.
The SJB also monitors the windshield wiper motor status by sending a voltage signal to the wiper/washer
module. When the windshield wiper is on (except during a mist wipe or while the wipers are on to clear
washer fluid during a wash condition), the wiper/washer module grounds the circuit to indicate to the SJB that
the wipers are on.

An on-demand DTC that may set when the SJB detects a short to
• B1696 - Autolamp On ground from the autolamps on input circuit.
Circuit Short To Ground
An on-demand DTC that sets when the SJB detects an open or short to
• B1791 - Autolamp Sensor voltage from the light sensor input circuit.
Input Circuit Open
A continuous and on-demand DTC that sets when the SJB detects a
• B1793 - Autolamp Sensor short to ground from the light sensor input circuit.
Input Circuit Short to
Ground
An on-demand DTC that sets when the SJB detects a short to ground
• B2008 - Wipers On Signal from the wipers on input circuit.

• Light sensor
• Headlamp switch
• Wiper/washer module
• SJB

PINPOINT TEST H: THE AUTOLAMPS ARE ON CONTINU

H1 CHECK THE SJB AUTOLAMP ON REQUEST PID
Yes
SJB DataLogger. No
• NOTE: Make sure the headlamp switch is in the OFF GO to H2 .
position.
• While placing the headlamp switch in the
AUTOLAMPS ON and then OFF position, monitor
the SJB headlamp switch PID (HDLMP_AUT_CKT).
• Does the PID indicate ON with the headlamp
switch in the AUTOLAMPS ON position and OFF
when the headlamp switch is in the OFF position?
H2 CHECK FOR A VOLTAGE SIGNAL TO THE
HEADLAMP SWITCH
Yes
• Ignition OFF. INSTALL a new headlamp switch.
• Disconnect: Headlamp Switch C205. REFER to Headlamp Switch in this
• Measure the voltage between the headlamp switch section. TEST the system for normal
C205-4, circuit CLF19 (VT/GN), harness side and operation.
ground.
No
GO to H3 .
• Is voltage greater than 10 volts?

H3 CHECK THE AUTOLAMPS REQUEST INPUT
Yes
• Disconnect: SJB C2280b. GO to H4 .
• Measure the resistance between the headlamp switch
C205-4, circuit CLF19 (VT/GN), harness side and No
ground. REPAIR circuit CLF19 (VT/GN) for a
short to ground. TEST the system for
normal operation.
PINPOINT TEST H: THE AUTOLAMPS ARE ON CONTINU 6003


H4 CHECK THE AUTOLAMPS REQUEST INPUT
CIRCUIT FOR AN OPEN
Yes
• Measure the resistance between the headlamp switch GO to H15 .
C205-4, circuit CLF19 (VT/GN), harness side and the
SJB C2280b-50, circuit CLF19 (VT/GN), harness No
side. REPAIR circuit CLF19 (VT/GN) for an
operation.

H5 USE THE RECORDED DTCs FROM THE SJB
SELF-TEST
Yes
• Check the recorded results from the SJB self-test. For DTC B2008, GO to H7 . For DTC
• Was DTC B2008, B1791 or B1793 recorded? B1791, GO to H9 . For DTC B1793, GO
to H13 .
No
GO to H6 .
H6 CHECK FOR VOLTAGE TO THE LIGHT SENSOR
(NO DTCs)
Yes
• Ignition OFF. INSTALL a new light sensor. REFER to
• Disconnect: Light Sensor C286 or C287. Light Sensor in this section. TEST the
• Place the headlamp switch in the AUTOLAMPS ON
position. No
• For vehicles with automatic temperature control, GO to H15 .

• For vehicles with manual temperature control,

measure the voltage between the light sensor C287-A,

H7 CHECK THE WIPER/WASHER MODULE
Yes
• Disconnect: Wiper/Washer Module C2157.
• Ignition ON. No
• Enter the following diagnostic mode on the scan tool: INSTALL a new wiper/washer module.
SJB Self-Test. REFER to Section 501-16 . CLEAR the
• Repeat the SJB self-test. DTCs. REPEAT the self-test.
• Is DTC B2008 still present?
H8 CHECK THE WIPERS ON INPUT CIRCUIT FOR A
SHORT TO GROUND
Yes
• Disconnect: SJB C2280f.
• Measure the resistance between the wiper/washer No
module C2157-2, circuit CRW01 (WH), harness side REPAIR circuit CRW01 (WH) for a
and ground. short to ground. CLEAR the DTCs.

H9 CHECK FOR VOLTAGE TO THE LIGHT SENSOR
(DTC B1791)


• Disconnect: Light Sensor C286. GO to H12 .
• Ignition ON.
• Place the headlamp switch in the AUTOLAMPS ON No
position. GO to H10 .
• For vehicles with automatic temperature control,


H10 CHECK THE LIGHT SENSOR INPUT CIRCUIT
Yes
• Ignition OFF. REPAIR circuit VLF14 (BU/BN) for a
• Place the headlamp switch in the OFF position. short to voltage. CLEAR the DTCs.
• Disconnect: SJB C2280b. REPEAT the self-test.
• Ignition ON.
• For vehicles with automatic temperature control, No
measure the voltage between the light sensor C286-2, GO to H11 .



FOR AN OPEN
Yes
• For vehicles with automatic temperature control,
measure the resistance between the light sensor No
C286-2, circuit VLF14 (BU/BN), harness side and the REPAIR circuit VLF14 (BU/BN) for an
SJB C2280b-46, circuit VLF14 (BU/BN), harness open. CLEAR the DTCs. REPEAT the
side. self-test.

measure the resistance between the light sensor
C287-A, circuit VLF14 (BU/BN), harness side and the
SJB C2280b-46, circuit VLF14 (BU/BN), harness
side.

H12 CHECK FOR VOLTAGE TO THE LIGHT
SENSOR USING THE CONNECTOR GROUND
Yes
• For vehicles with automatic temperature control, INSTALL a new light sensor. REFER to
measure the voltage between the light sensor C286-2, Light Sensor in this section. CLEAR the
circuit VLF14 (BU/BN), harness side and the light DTCs. REPEAT the self-test.
sensor C286-4, circuit GD116 (BK/VT), harness side.
No

self-test.

circuit VLF14 (BU/BN), harness side and the light
sensor C287-B, circuit GD116 (BK/VT), harness side.

H13 CHECK FOR VOLTAGE TO THE LIGHT
SENSOR (DTC B1793)
Yes
• Disconnect: Light Sensor C286. INSTALL a new light sensor. REFER to
• Ignition ON. Light Sensor in this section. CLEAR the
• Place the headlamp switch in the AUTOLAMPS ON DTCs. REPEAT the self-test.
position.
measure the voltage between the light sensor C286-2, GO to H14 .



Yes
measure the resistance between the light sensor REPAIR circuit VLF14 (BU/BN) for a
C286-2, circuit VLF14 (BU/BN), harness side and short to ground. CLEAR the DTCs.
ground. REPEAT the self-test.

measure the resistance between the light sensor
C287-A, circuit VLF14 (BU/BN), harness side and
ground.

H15 CHECK FOR CORRECT SJB OPERATION
Yes
• Ignition OFF. INSTALL a new SJB . REFER to
• Disconnect all the SJB connectors. Section 419-10 . TEST the system for
• Check for: normal operation.
♦ corrosion
♦ damaged pins No
♦ pushed-out pins The system is operating correctly at this
• Connect all the SJB connectors and make sure they time. The concern may have been caused
seat correctly. by a loose or corroded connector.
• Operate the system and verify the concern is still CLEAR the DTCs. REPEAT the
present. self-test.



Manual
Stoplamps
Special Tool(s)


Flex Probe Kit
Fusion
When the brake pedal is applied, voltage is routed to the SJB and the high mounted stoplamp. The SJB then
supplies voltage to the rear stoplamps. The rear stoplamps are combination stop/turn lamps. The turn and
hazard lamp functions override the rear stoplamp function.
MKZ
When the brake pedal is applied, voltage is routed to the high mounted stoplamp, the rear stoplamps and the
SJB .
• Stoplamp • Smart Junction Box (SJB) fuse 2 (15A) (stoplamp
switch switch)
Stoplamps 6011
• Bulb(s)
• Rear lamp assembly
• SJB



418-00 .
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test I: All The Stoplamps Are Inoperative
Refer to Wiring Diagrams Cell 90 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Turn Signal/Stop/Hazard
Lamps for schematic and connector information.
MKZ 6012
Normal Operation
The stoplamp switch is supplied voltage from the Smart Junction Box (SJB) fuse 2 (15A). When the brake
pedal is applied, the stoplamp switch routes voltage to the stoplamps and the SJB .
• Fuse
• Stoplamp switch
• SJB
PINPOINT TEST I: ALL THE STOPLAMPS ARE INOPERATIVE

I1 CHECK FOR VOLTAGE TO THE STOPLAMP
SWITCH
Yes
• Disconnect: Stoplamp Switch C278.
• Measure the voltage between the stoplamp switch No
C278-1, circuit SBP02 (YE/RD), harness side and VERIFY the SJB fuse 2 (15A) is OK. If
ground. OK, GO to I3 . TEST the system for
normal operation. If not OK, REFER to
the Wiring Diagrams Manual to identify
the possible causes of the circuit short.

I2 BYPASS THE STOPLAMP SWITCH
Yes
• Connect a fused jumper wire between the stoplamp REMOVE the jumper wire. INSTALL a
switch C278-1, circuit SBP02 (YE/RD), harness side new stoplamp switch. REFER to
and the stoplamp switch C278-4, circuit CCB08 Stoplamp Switch in this section. TEST
(VT/WH), harness side. the system for normal operation.
No
REMOVE the jumper wire. REPAIR
circuit CCB08 (VT/WH) for an open.

• Do the stoplamps illuminate?

I3 CHECK CIRCUIT SBP02 (YE/RD) FOR AN OPEN
Yes
• Disconnect: SJB C2280d. GO to I4 .
• Measure the resistance between the stoplamp switch
C278-1, circuit SBP02 (YE/RD), harness side and the No
SJB C2280d-13, circuit SBP02 (YE/RD), harness side. REPAIR SBP02 (YE/RD) for an open.

I4 CHECK FOR CORRECT SJB OPERATION
Yes
♦ damaged pins
• Is the concern still present? self-test.
Pinpoint Test J: One Or More Stoplamps Are Inoperative - Fusion
Normal Operation
When the brake pedal is applied, the stoplamp switch routes voltage to the high moted stoplamp and the Smart
Junction Box (SJB). When the SJB detects the brake pedal is applied, the SJB provides voltage to the LH and
RH rear stoplamps. Each stoplamp has an independent ground circuit.
NOTE: SJB fuse 6 (20A) supplies voltage for both combination rear stop/turn lamps and both front turn
lamps.
PINPOINT TEST I: ALL THE STOPLAMPS ARE INOPERATIVE 6014

• B106E - A continuous DTC that sets when the SJB has temporarily shut down the output driver.
Solid The module has temporarily disabled a stoplamp output because an excessive
State current draw exists (such as a short to ground). The SJB cannot enable the stoplamp
Driver output until the cause of the short is corrected, the DTCs have been cleared and a
Disabled successful lf-test is run.
Due to
Short
Circuit
A continuous DTC that sets when the SJB has permanently shut down the output driver.
• B106F - The module has permanently disabled a stoplamp output because an excessive
Module current draw fault (such as a short to ground) has exceeded the limits that the SJB
Disabled can withstand. The cause of the excessive current draw MUST be corrected before a
Due to new SJB is installed.
External
Fault
A continuous and on-demand DTC that may set when the SJB detects a short to ground
• B2044 - from the LH rear stop/turn lamp voltage supply circuit.
Left Rear
Stop
Lamp
Circuit
Short to
Ground
An on-demand DTC that sets when the SJB detects an open from the LH rear stop/turn
• B2045 - lamp voltage supply circuit.
Left Rear
Stop
Lamp
Circuit
Open
A continuous and on-demand DTC that may set when tan title="Smart Junction Box"
• B2046 - class="popup" onmouseover="this.className='popupnounderline';"
Right onmouseout="this.className='popup';">SJB detects a short to ground from the RH rear
Rear Stop stop/turn lamp voltage supply circuit.
Lamp
Circuit
Short to
Ground
An on-demand DTC that sets when the SJB detects an open from the RH rear stop/turn
Right
Rear Stop
Lamp
Circuit
Open

• Bulb holder
• SJB

PINPOINT TEST J: ONE OR MORE STOPLAMPS ARE INOPERATIVE - FUSION

J1 DETERMINE THE INOPERATIVE STOPLAMP
Yes
• Ignition OFF. G Pinpoint Test I .
• Apply the brake pedal and observe the stoplamps.
• Are all the stoplamps inoperative? No
For the high mounted stoplamp,
GO to J2 .
If only one side (the LH or RH

rear stoplamp) is inoperative,
GO to J5 .
If both sides (LH and RH rear

stoplamps) are inoperative,
VERIFY the SJB fuse 6 (20A)
is OK. If OK, GO to J4 . If not
OK, REFER to the Wiring
Diagrams Manual to identify
the possible causes of the
circuit short. After the repair:
If no DTCs are present, TEST

operation.
If DTC B106E is present,

CLEAR the DTCs and
REPEAT the self-test
(required to enable the
stoplamp output driver if
DTC B106E is present) .
operation.
If DTC B106F is present,

J2 CHECK FOR VOLTAGE TO THE HIGH MOUNTED
STOPLAMP
PINPOINT TEST J: ONE OR MORE STOPLAMPS ARE INOPERATIVE - FUSION 6016

NOTE: The Fusion high mounted stoplamp has 9 LEDs Yes

mounted in the center third portion of the assembly. The outer GO to J3 .
left and right portions of the high mounted stoplamp are not
illuminated. The high mounted stoplamp is not designed to No
illuminate the full width of the lens. REPAIR circuit CCB08
• Disconnect: High Mounted Stoplamp C4233. the system for normal
• While applying the brake pedal, measure the voltage between operation.
the high mounted stoplamp C4233-2, circuit CCB08 (VT/WH),

J3 CHECK FOR VOLTAGE TO THE HIGH MOUNTED
STOPLAMP USING THE CONNECTOR GROUND
Yes
• While applying the brake pedal, measure the voltage between INSTALL a new high mounted
the high mounted stoplamp C4233-2, circuit CCB08 (VT/WH), stoplamp. TEST the system for
harness side and the high mounted stoplamp C4233-1, circuit normal operation.
GD171 (BK/GY), harness side.
No
(BK/GY) for an open. TEST
operation.

J4 CHECK FOR VOLTAGE TO THE SJB
Yes
• Disconnect: SJB C2280b. GO to J11 .
• While applying the brake pedal, measure the voltage between
the SJB C2280b-40, circuit CCB08 (VT/WH), harness side and No
ground. REPAIR circuit CCB08
(VT/WH) for an open. CLEAR
self-test.


J5 USE THE RECORDED DTCs FROM THE SJB SELF-TEST
Yes
• Check the recorded results from the SJB on-demand self-test. GO to J6 .
• Is DTC B2045 or DTC B2047 present?
No
GO to J9 .
J6 CHECK FOR VOLTAGE TO THE INOPERATIVE
STOPLAMP
Yes
• Disconnect: Inoperative Rear Lamp. GO to J7 .
the LH rear lamp C412-3, circuit CLS18 (GY/BN), harness side No
and ground; or between the RH rear lamp C415-3, circuit GO to J8 .
CLS19 (VT/OG), harness side and ground.

J7 CHECK FOR VOLTAGE TO THE INOPERATIVE
Yes
• While applying the brake pedal, measure the voltage between INSTALL a new bulb holder.
the LH rear lamp C412-3, circuit CLS18 (GY/BN), harness side CLEAR the DTCs. REPEAT
and the LH rear lamp C412-1, circuit GD171 (BK/GY), harness the self-test.
side; or between the RH rear lamp C415-3, circuit CLS19
(VT/OG), harness side and the RH rear lamp C415-3, circuit No
GD171 (BK/GY), harness side. REPAIR circuit GD171
(BK/GY) for an open. CLEAR
self-test.

J8 CHECK THE SJB STOPLAMP OUTPUT CIRCUIT FOR AN
OPEN

• Disconnect: SJB C2280d. Yes

• Measure the resistance between the LH rear lamp C412-3, GO to J11 .
circuit CLS18 (GY/BN), harness side and the SJB C2280d-25,
circuit CLS18 (GY/BN), harness side; or between the RH rear No
lamp C415-3, circuit CLS19 (VT/OG), harness side and the SJB REPAIR circuit CLS18
C2280d-26, circuit CLS18 (GY/BN), harness side. (GY/BN) (LH rear stoplamp) or
circuit CLS19 (VT/OG) (RH
rear stoplamp) for an open.
the self-test.

J9 CHECK THE BULB HOLDER FOR A SHORT TO GROUND
Yes
• Disconnect: Inoperative Rear Lamp. INSTALL a new bulb holder.
• Ignition ON. TEST the system for normal
• Enter the following diagnostic mode on the scan tool: SJB operation.
Self-Test.
• Clear the DTCs and repeat the self-test (required to enable the No
turn lamp output driver if DTC B106E is present) . GO to J10 .
the LH rear lamp C412-3, circuit CLS18 (GY/BN), harness side
and ground; or between the RH rear lamp C415-3, circuit
CLS19 (VT/OG), harness side and ground.

J10 CHECK THE SJB STOPLAMP OUTPUT CIRCUIT FOR A
SHORT TO GROUND
Yes
• Disconnect: SJB C2280d.
• Measure the resistance between the SJB C2280d-25, circuit No
CLS18 (GY/BN), harness side and ground; or between the SJB REPAIR circuit CLS18
C2280d-26, circuit CLS19 (VT/OG), harness side and ground. (GY/BN) (LH rear stoplamp) or
circuit CLS19 (VT/OG) (RH
rear stoplamp) for a short to
ground. After the repair:
If no DTCs are present, TEST


operation.

CLEAR the DTCs and
(required to enable the turn
lamp output driver if DTC
B106E is present) . TEST the

J11 CHECK FOR CORRECT SJB OPERATION
Yes
♦ damaged pins
Pinpoint Test K: One Or More Stoplamps Are Inoperative - MKZ
Normal Operation
When the brake pedal is applied, the stoplamp switch routes voltage to the high mounted stoplamp and both
rear stoplamps. Each stoplp has an independent ground circuit.

PINPOINT TEST K: ONE OR MORE STOPLAMPS ARE INOPERATIVE - MKZ

K1 DETERMINE THE INOPERATIVE STOPLAMP


• Apply the brake pedal and observe the stoplamps. GO to Pinpoint Test I .
• Are all the stoplamps inoperative?
No
For the high mounted
stoplamp, GO to K2 .
For a LH or RH rear
stoplamp, GO to K4 . /td>
K2 CHECK FOR VOLTAGE TO THE HIGH MOUNTED
STOPLAMP
Yes
• Disconnect: High Mounted Stoplamp. GO to K3 .
• While applying the brake pedal, measure the voltage between the
high mounted stoplamp C475-1, circuit CCB08 (VT/WH), harness No
side and ground. REPAIR circuit CCB08
operation.

K3 CHECK FOR VOLTAGE TO THE HIGH MOUNTED
Yes
• While applying the brake pedal, measure the voltage between the INSTALL a new high
high mounted stoplamp C475-1, circuit CCB08 (VT/WH), harness mounted stoplamp. REFER
side and the high mounted stoplamp C475-2, circuit GD171 to High Mounted Stoplamp
(BK/GY), harness side. in this section. TEST the
No
operation.

K4 CHECK FOR VOLTAGE TO THE LH STOPLAMP
Yes
• Disconnect: Inoperative Rear Stoplamp. GO to K5 .
• While applying the brake pedal, measure the voltage between the
LH rear lamp C419-1, circuit CCB08 (VT/WH), harness side and No
ground; or between the RH rear lamp C418-1, circuit CCB08 REPAIR circuit CCB08
(VT/WH), harness side and ground. (VT/WH) for an open. TEST
operation.
PINPOINT TEST K: ONE OR MORE STOPLAMPS ARE INOPERATIVE - MKZ 6021


K5 CHECK FOR VOLTAGE TO THE INOPERATIVE
Yes
• While applying the brake pedal, measure the voltage between the INSTALL a new rear lamp
LH rear lamp C419-1, circuit CCB08 (VT/WH), harness side and assembly. REFER to Rear
the LH rear lamp C419-3, circuit GD171 (BK/GY), harness side; Lamp Assembly in this
or between the RH rear lamp C418-1, circuit CCB08 (VT/WH), section. TEST the system
harness side and the RH rear lamp C418-3, circuit GD171 for normal operation.
No
operation.
Pinpoint Test L: The Stoplamps Are On Continuously
Normal Operation
When the brake pedal is applied, the stoplamp switch routes voltage to the LH and RH rear stoplamps (MKZ),
the Smart Junction Box (SJB), the high mounted stoplamp and the PCM.
For Fusion, when the SJB detects the brake pedal is applied, the SJB provides voltage to the LH and RH rear
stoplamps.
• DTC B1485 (Brake Pedal Input Short to Battery) - an on-demand DTC that sets when the SJB detects
a short to voltage from the stoplamp switch input circuit.
• DTC B2045 (Left Rear Stop Lamp Circuit Open) - an on-demand DTC that sets when the SJB detects
a short to voltage from the LH rear stop/turn lamp output circuit.
• DTC B2047 (Right Rear Stop Lamp Circuit Open) - an on-demand DTC that sets when the SJB
detects a short to voltage from the RH rear stop/turn lamp output circuit.

• Stoplamp switch
• PCM
• SJB
PINPOINT TEST L: THE STOPLAMPS ARE ON CONTINUOUSLY

L1 DETERMINE IF ALL THE
STOPLAMPS ARE ILLUMINATED
Yes
• Observe the stoplamps with the
brake pedal released. No
• Are all of the stoplamps GO to L2 .
illuminated?
L2 CHECK THE SJB STOPLAMP
OUTPUT CIRCUIT FOR A SHORT
TO VOLTAGE
Yes
• Disconnect: SJB C2280d. If the LH rear lamp continues to illuminate, REPAIR circuit
• Do the stoplamps continue to CLS18 (GY/BN) for a short to voltage. CLEAR the DTCs.
illuminate? REPEAT the self-test. If the RH rear lamp continues to
illuminate, REPAIR circuit CLS19 (VT/OG) for a short to
voltage. CLEAR the DTCs. REPEAT the self-test.
No
GO to L7 .
L3 CHECK THE STOPLAMP
SWITCH
Yes
• Disconnect: Stoplamp Switch GO to L4 .
C278.
• Do the stoplamps continue to No
illuminate? INSTALL a new stoplamp switch. REFER to Stoplamp
Switch in this section. CLEAR the DTCs. REPEAT the
self-test.
L4 CHECK THE PCM
Yes
• Disconnect: PCM C175b. GO to L5 .
• Do the stoplamps continue to
illuminate? No
GO to L6 .
L5 CHECK THE STOPLAMP
SWITCH OUTPUT CIRCUIT FOR A
SHORT TO VOLTAGE
Yes
• Disconnect: SJB C2280b. REPAIR circuit CCB08 (VT/WH) for a short to voltage.
• Does the high mounted CLEAR the DTCs. REPEAT the self-test.
stoplamp continue to
illuminate? No
PINPOINT TEST L: THE STOPLAMPS ARE ON CONTINUOUSLY 6023

GO to L7 .
L6 CHECK FOR CORRECT PCM
OPERATION
Yes
• Disconnect all the PCM INSTALL a new PCM. REFER to Section 303-14A , Section
connectors. 303-14B , Section 303-14C or Section 303-14D . TEST the
• Check for: system for normal operation.
♦ corrosion
♦ damaged pins No
♦ pushed-out pins The system is operating correctly at this time. The concern
• Connect all the PCM connectors may have been caused by a loose or corroded connector.
and make sure they seat CLEAR the DTCs. REPEAT the self-test.
correctly.
L7 CHECK FOR CORRECT SJB
OPERATION
Yes
• Disconnect all the SJB INSTALL a new SJB . REFER to Section 419-10 . TEST the
connectors. system for normal operation.
• Check for:
♦ corrosion No
♦ damaged pins The system is operating correctly at this time. The concern
♦ pushed-out pins may have been caused by a loose or corroded connector.
• Connect all the SJB connectors CLEAR the DTCs. REPEAT the self-test.
and make sure they seat
correctly.
PINPOINT TEST L: THE STOPLAMPS ARE ON CONTINUOUSLY 6024


Manual
Turn Signal and Hazard Lamps
Special Tool(s)


Flex Probe Kit
The Smart Junction Box (SJB) monitors the multifunction switch position by sending voltage signals (for the
LH and RH turn input) to the multifunction switch. When the multifunction switch is in the LH or RH TURN
positions that input signal is switched to ground.
The SJB monitors the request for the hazard lamps by sending a voltage signal to the hazard flasher lamp
switch. For MKZ, the hazard flasher lamp switch is integrated into the Front Controls Interface Module
(FCIM).
When the SJB receives a request for a turn signal or hazard lamps, the SJB supplies voltage to the appropriate
turn lamps.
• Multifunction • Smart Junction Box (SJB) fuse 6

switch (20A)
Turn Signal and Hazard Lamps 6025

• Hazard flasher • Bulbs

lamp switch • SJB



418-00 .
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test M: The Turn Signal Lamps Are Inoperative
Turn Signal and Hazard Lamps 6026

Normal Operation
The Smart Junction Box (SJB) sends voltage signals to the multifunction switch. When the multifunction
switch is switched to the LH or RH TURN positions, the voltage signal is switched to ground. When the SJB
detects the multifunction switch in the LH or RH TURN position, the SJB sends voltage to the appropriate
turn lamps.
• Fuse
• SJB
PINPOINT TEST M: THE TURN SIGNAL LAMPS ARE INOPERATIVE

M1 CHECK FOR CORRECT HIGH BEAM
OPERATION
Yes
• Place the headlamp switch in the HEADLAMPS ON PLACE the headlamp switch in the
position. OFF position. For Fusion, GO to M2 .
• Place the multifunction switch in the HIGH BEAM For MKZ, VERIFY the SJB fuse 6
position while observing the high beam headlamps. (20A) is OK. If OK, GO to M3 . If not
• Do the high beams illuminate? OK, REFER to the Wiring Diagrams
No
PLACE the headlamp switch in the
OFF position. GO to Pinpoint Test A .
M2 CHECK FOR CORRECT STOPLAMP OPERATION
Yes
• Apply and release the brake pedal. GO to M3 .
• Do the stoplamps operate correctly?
No
REFER to Stoplamps in this section.
M3 BYPASS THE MULTIFUNCTION SWITCH
Yes
• Ignition OFF. REMOVE the jumper wire. INSTALL a
• For an inoperative LH turn signal, connect a fused Section 211-05 . TEST the system for
jumper wire between the multifunction switch C202-2, normal operation.
circuit CLS39 (VT/WH), harness side and the
multifunction switch C202-8, circuit GD116 (BK/VT), No
harness side. REMOVE the jumper wire. GO to M4 .

• For an inoperative RH turn signal, connect a fused

jumper wire between the multifunction switch C202-3,
circuit CLS41 (GY/YE), harness side and the
multifunction switch C202-8, circuit GD116 (BK/VT),
harness side.
• Ignition ON.
• Do the turn signals in question flash on and off?
M4 CHECK THE TURN SIGNAL REQUEST INPUT
CIRCUIT FOR AN OPEN
Yes
• Disconnect: SJB C2280b. GO to M5 .
• For an inoperative LH turn signal, measure the
resistance between the multifunction switch C202-2, No
circuit CLS39 (VT/WH), harness side and the SJB REPAIR circuit CLS39 (VT/WH) (LH
C2280b-42, circuit CLS39 (VT/WH), harness side. turn signal) or circuit CLS41 (GY/YE)
(RH turn signal) for an open. TEST the
• For an inoperative RH turn signal, measure the

resistance between the multifunction switch C202-3,
circuit CLS41 (GY/YE), harness side and the SJB
C2280b-29, circuit CLS41 (GY/YE), harness side.
PINPOINT TEST M: THE TURN SIGNAL LAMPS ARE INOPERATIVE 6028


M5 CHECK FOR CORRECT SJB OPERATION
Yes
♦ damaged pins
present. connector.
Pinpoint Test N: The Turn Signal Lamps Are Always On
Normal Operation
The Smart Junction Box (SJB) sends voltage signals to the multifunction switch. When the multifunction
switch is switched to the LH or RH TURN positions, the voltage signal is switched to ground. When the SJB
detects the multifunction switch is in the LH or RH TURN position, the SJB sends voltage to the appropriate
turn lamps.
• DTC B2281 (Right Turn Switch Short to Ground) - an on-demand DTC that sets when the SJB
detects a short to ground from the RH turn signal input circuit.
• DTC B2282 (Left Turn Switch Short to Ground) - an on-demand DTC that sets when the SJB detects
a short to ground from the LH turn signal switch input circuit.

• SJB
PINPOINT TEST N: THE TURN SIGNAL LAMPS ARE ALWAYS ON

N1 CHECK THE MULTIFUNCTION SWITCH


• Disconnect: Multifunction Switch C202. GO to N2 .
• Ignition ON.
• Do the turn lamps continue to flash on and off? No
INSTALL a new multifunction
switch. REFER to Section 211-05 .
self-test.
N2 CHECK THE TURN SIGNAL REQUEST INPUT
Yes
• Measure the resistance between the multifunction switch No
C202-2, (LH turn lamps), circuit CLS39 (VT/WH), REPAIR circuit CLS39 (VT/WH)
harness side and ground; or between the multifunction (LH turn signal) or circuit CLS41
switch C202-3, (RH turn lamps), circuit CLS41 (GY/YE) (RH turn signal) for a short
(GY/YE), harness side and ground. to ground. CLEAR the DTCs.

N3 CHECK FOR CORRECT SJB OPERATION
Yes
♦ damaged pins
• Is the concern still present? connector. CLEAR any DTCs.
Pinpoint Test O: One Turn Signal/Hazard Lamp Is Inoperative/Always On
Normal Operation
When the Smart Junction Box (SJB) detects the multifunction switch is in the LH TURN position, the SJB
provides voltage to the LH front turn lamp and LH rear turn lamp. When the SJB detects the multifunction
switch is in the RH TURN position, the SJB provides voltage to the RH front turn lamp and the RH rear turn
lamp.
PINPOINT TEST N: THE TURN SIGNAL LAMPS ARE ALWAYS ON 6030


A contious DTC that sets when the SJB has temporarily shut down the output driver.
• B106E - The module has temporarily disabled a turn lamp output because an excessive
Solid State current draw exists (such as a short to ground). The SJB cannot enable the turn
Driver lamp output until the cause of the short is corrected, the DTCs have been cleared
Disabled Due and a successful self-test is run.
to Short
Circuit
• B106F - driver. The module has permanently disabled a turn lamp output because an
Module excessive current draw fault (such as a short to ground) has exceeded the limits
Disabled Due that the SJB can withstand. The cause of the excessive current draw MUST be
to External corrected before a new SJB is installed.
Fault
• B2048 - Left from the LH rear turn lamp voltage supply circuit. >
Rear Turn
Lamp Circuit
Short to
Ground
An on-demand DTC that sets when the SJB detects an open from the LH rear turn
• B2049 - Left lamp voltage supply circuit.
Rear Turn
Lamp Circuit
Open
• B2050 - from the RH rear turn lamp voltage supply circuit.
Right Rear
Turn Lamp
Circuit Short
to Ground
An on-demand DTC that sets when the SJB detects an open from the RH rear turn
Right Rear
Turn Lamp
Circuit Open
An on-demand DTC that sets when the SJB detects an open or short to voltage from
• B2A27 - the RH front turn lamp voltage supply circuit.
Right Front
Turn Lamp
Circuit Open
A continuous and on-demand DTC that sets when the SJB detects ground from the RH
• B2A28 - front turn lamp voltage supply circuit.
Right Front
Turn Lamp
Circuit Short
to Ground
An on-demand DTC that sets when the SJB detects an open or short to voltage from
the LH front turn lamp voltage supply circuit.

• B2A29 - Left
Front Turn
Lamp Circuit
Open
• B2A2A - Left from the LH front turn lamp voltage supply circuit.
Front Turn
Lamp Circuit
Short to
Ground

• Bulb holder
• SJB
PINPOINT TEST O: ONE TURN SIGNAL/HAZARD LAMP IS INOPERATIVE/ALWAYS ON

O1 CHECK THE STOPLAMPS
Yes
• Apply and release the brake pedal while observing the GO to O2 .
stoplamps.
• Do the stoplamps operate correctly? No
REFER to Stoplamps in this section.
O2 DETERMINE IF A TURN LAMP IS ALWAYS ON
Yes
• Monitor the turn lamps while placing the multifunction
switch in the RH TURN and then LH TURN positions. No
• Is any turn lamp always on? GO to O4 .
O3 CHECK THE SJB TURN LAMP OUTPUT CIRCUIT
Yes
• Ignition OFF. REPAIR circuit CLS21 (BU/GN)
• Disconnect: SJB C2280f (Front Turn Lamp). (LH front), circuit CLS25 (YE/VT)
• Disconnect: SJB C2280c (Rear Turn Lamp). (RH front), circuit CLS23 (GY/OG)
• Ignition ON. (LH rear) or circuit CLS24
• Does the turn lamp in question continue to illuminate? (BN/WH) (RH rear) for a short to
voltage. CLEAR the DTCs.
No
GO to O10 .
PINPOINT TEST O: ONE TURN SIGNAL/HAZARD LAMP IS INOPERATIVE/ALWAYS ON 6032

O4 USE THE RECORDED DTCs FROM THE SJB

SELF-TEST
Yes
• Check the recorded results from the SJB on-demand GO to O5 .
self-test.
• Is DTC B2049, B2051, B2A27 or B2A29 present? No
GO to O8 .
O5 CHECK FOR VOLTAGE TO THE TURN LAMP (OPEN
DTC PRESENT)
Yes
• Disconnect: Inoperative Turn Lamp.
• Activate the hazard flasher lamp function. No
• For a front lamp, measure the voltage between the LH GO to O7 .
front turn lamp C1023-3, circuit CLS21 (BU/GN), harness
side and ground; or between the RH front turn lamp
C1043-3, circuit CLS25 (YE/VT), harness side and
ground.
• For an MKZ rear turn lamp, measure the voltage between

the LH rear turn lamp C4139-1, circuit CLS23 (GY/OG),
harness side and ground; or between the RH front turn
lamp C4140-1, circuit CLS24 (BN/WH), harness side and
ground.
• Does the voltage alternate from 0 volts to greater than

10 volts?
O6 CHECK FOR VOLTAGE TO THE FRONT TURN
LAMP USING THE CONNECTOR GROUND
Yes
• For a front lamp, measure the voltage between the LH For a front lamp, INSTALL a new
front turn lamp C1023-3, circuit CLS21 (BU/GN), harness bulb holder. TEST the system for
side and the LH front turn lamp C1023-1, circuit GD123 normal operation. For an MKZ rear
(BK/GY), harness side; or between the RH front turn lamp lamp, INSTALL a new rear lamp
C1043-3, circuit CLS25 (YE/VT), harness side and the RH assembly. REFER to Rear Lamp
front turn lamp C1043-1, circuit GD121 (BK/YE), harness Assembly in this section. TEST the

side. system for normal operation.
No
REPAIR circuit GD123 (BK/GY)
(LH front), circuit GD121 (BK/YE)
(RH front) or circuit GD171
(BK/GY) (LH or RH rear) for an
operation.

harness side and the LH rear turn lamp C4139-2, circuit
GD171 (BK/GY), harness side; or between the RH front
turn lamp C4140-1, circuit CLS24 (BN/WH), harness side
and the RH front turn lamp C4140-2, circuit GD171
• Does the voltage alternate from 0 volts to greater than

10 volts?
FOR AN OPEN
Yes
• Turn the hazard lamp function off. GO to O10 .
• Disconnect: SJB C2280f (Front Turn Lamp).
• Disconnect: SJB C2280c (Rear Turn Lamp). No
• For a front lamp, measure the resistance between the LH REPAIR circuit CLS21 (BU/GN)
front turn lamp C1023-3, circuit CLS21 (BU/GN), harness (LH front), circuit CLS25 (YE/VT)
side and the SJB C2280f-21, circuit CLS21 (BU/GN), (RH front), circuit CLS23 (GY/OG)
harness side; or between the RH front turn lamp C1043-3, (LH rear) or circuit CLS24
circuit CLS21 (BU/GN), harness side and the SJB (BN/WH) (RH rear) for an open.
C2280f-23, circuit CLS25 (YE/VT), harness side. TEST the system for normal
operation.

harness side and the SJB C2280c-21, circuit CLS23

(GY/OG), harness side; or between the RH front turn lamp

C4140-1, circuit CLS24 (BN/WH), harness side and the
SJB C2280c-19, circuit CLS24 (BN/WH), harness side.

O8 ISOLATE THE BULB HOLDER OR REAR LAMP
ASSEMBLY AS THE CAUSE OF THE SHORT TO
GROUND
Yes
• Ignition OFF. INSTALL a new bulb holder or rear
• Disconnect: Inoperative Turn Lamp. lamp assembly in question. TEST
Self-Test. No
• Clear the DTCs and repeat the self-test (required to GO to O9 .
enable the turn lamp output driver if DTC B106E is
present) .
• Activate the hazard flasher lamp function.
• For a front lamp, measure the voltage between the LH
front turn lamp C1023-3, circuit CLS21 (BU/GN), harness
side and ground; or between the RH front turn lamp
C1043-3, circuit CLS25 (YE/VT), harness side and
ground.

harness side and ground; or between the RH front turn
lamp C4140-1, circuit CLS24 (BN/WH), harness side and
ground.

• Does the voltage alternate from 0 to greater than 10

volts?
Yes
• Turn the hazard lamp function off. GO to O10 .
• Ignition OFF.
• Disconnect: SJB C2280f (Front Turn Lamp). No
• Disconnect: SJB C2280c (Rear Turn Lamp). REPAIR circuit CLS21 (BU/GN)
• For a front turn lamp, measure the resistance between the (LH front), circuit CLS25 (YE/VT)
SJB C2280f-21 (LH turn lamp), circuit CLS21 (BU/GN), (RH front), circuit CLS23 (GY/OG)
harness side and ground; or between the SJB C2280f-23 (LH rear) or circuit CLS24
(RH turn lamp), circuit CLS25 (YE/VT), harness side and (BN/WH) (RH rear) for a short to
ground. ground. After the repair:
If no DTCs are present, TEST the

If DTC B106E is present, CLEAR

the DTCs and REPEAT the self-test
(required to enable the turn lamp
output driver if DTC B106E is
present) . TEST the system for
normal operation.
• For a rear turn lamp, measure the resistance between the
SJB C2280c-21 (LH turn lamp), circuit CLS23 (GY/OG),
If DTC B106F is present, INSTALL
harness side and ground; or between the SJB C2280c-19
a new SJB . REFER to Section
(RH turn lamp), circuit CLS24 (BN/WH), harness side and
419-10 . TEST the system for
ground.
normal operation.

O10 CHECK FOR CORRECT SJB OPERATION
Yes
• Ignition OFF. INSTALL a new SJB . REFER to
• Disconnect all the SJB connectors. Section 419-10 . TEST the system
♦ corrosion
♦ damaged pins No
♦ pushed-out pins The system is operating correctly at

• Connect all the SJB connectors and make sure they seat this time. The concern may have
correctly. been caused by a loose or corroded
• Operate the system and verify the concern is still present. connector. CLEAR the DTCs.
• Is the concern still present? REPEAT the self-test.
Pinpoint Test P: The Hazard Lamps Are Inoperative/Always On
Normal Operation
The Smart Junction Box (SJB) sends a voltage signal to the hazard flasher lamp switch. When the hazard
flasher lamp switch is pressed, the voltage signal is routed to ground. When the SJB detects a request for the
hazard lamps, the SJB provides voltage to the appropriate turn lamps.
The hazard flasher lamp switch is a momentary contact switch.
The hazard flasher lamp switch for MKZ is integrated into the Front Controls Interface Module (FCIM).
• DTC B2071 (Hazard Switch Signal Short to Ground) - an on-demand DTC that sets when the SJB
detects a short to ground from the hazard flasher lamp switch input circuit.

• FCIM (MKZ)
• SJB
PINPOINT TEST P: THE HAZARD LAMPS ARE INOPERATIVE/ALWAYS ON

P1 CHECK THE RECORDED DTCs FROM
THE SJB SELF-TEST
Yes
• Check the recorded DTCs from the SJB GO to P2 .
self-test.
GO to P4 .
P2 CHECK THE HAZARD FLASHER LAMP
SWITCH
Yes
• Disconnect: Hazard Flasher Lamp Switch GO to P3 .
C2039 (Fusion).
• Disconnect: FCIM C2402 (MKZ). No
• Ignition ON. For Fusion, INSTALL a new hazard flasher lamp

• Enter the following diagnostic mode on the switch. REFER to Hazard Flasher Lamp Switch
scan tool: SJB Self-Test. in this section. TEST the system for normal
• Repeat the SJB self-test. operation. For MKZ, INSTALL a new FCIM .
• Is DTC B2071 still present? REFER to Section 415-00 TEST the system for
normal operation.
P3 CHECK THE HAZARD LAMP REQUEST
INPUT CIRCUIT FOR A SHORT TO GROUND
Yes
• For Fusion, measure the resistance between No
the hazard flasher lamp switch C2039-6, REPAIR circuit CLS32 (BN/YE) for a short to
circuit CLS32 (BN/YE), harness side and ground. CLEAR the DTCs. REPEAT the
ground. self-test.
• For MKZ, measure the resistance between the

FCIM C2402-6, circuit CLS32 (BN/YE),

P4 CHECK FOR A VOLTAGE SIGNAL TO
THE HAZARD FLASHER LAMP SWITCH OR
THE FCIM
Yes
• Ignition OFF. For Fusion, GO to P6 . For MKZ, INSTALL a
• Disconnect: Hazard Flasher Lamp Switch new FCIM . REFER to Section 415-00 . TEST
C2039 (Fusion). the system for normal operation.
• Disconnect: FCIM C2402 (MKZ).
• For Fusion, measure the voltage between the No
hazard flasher lamp switch C2039-6, circuit GO to P5 .
CLS32 (BN/YE), harness side and ground.
PINPOINT TEST P: THE HAZARD LAMPS ARE INOPERATIVE/ALWAYS ON 6038

• For MKZ, measure the voltage between the

FCIM C2402-6, circuit CLS32 (BN/YE),

P5 CHECK THE HAZARD LAMP REQUEST
INPUT CIRCUIT FOR AN OPEN
Yes
• For Fusion, measure the resistance between GO to P7 .
the SJB C2280b-48, circuit CLS32 (BN/YE),
harness side and the hazard flasher lamp No
switch C2039-6, circuit CLS32 (BN/YE), REPAIR circuit CLS32 (BN/YE) for an open.
harness side. TEST the system for normal operation.
• For MKZ, measure the resistance between the

SJB C2280b-48, circuit CLS32 (BN/YE),
harness side and the FCIM C2402-6, circuit
CLS32 (BN/YE), harness side.

P6 CHECK FOR VOLTAGE TO THE HAZARD
FLASHER LAMP SWITCH USING THE

CONNECTOR GROUND
Yes
• Measure the voltage between the hazard INSTALL a new hazard flasher lamp switch.
flasher lamp switch C2039-6, circuit CLS32 REFER to Hazard Flasher Lamp Switch in this
(BN/YE), harness side and the hazard lamp section. TEST the system for normal operation.
switch C2039-2, circuit GD116 (BK/VT),
harness side. No
REPAIR circuit GD116 (BK/VT) for an open.

P7 CHECK FOR CORRECT SJB OPERATION
Yes
• Disconnect all the SJB connectors. INSTALL a new SJB . REFER to Section 419-10
• Check for: . TEST the system for normal operation.
♦ corrosion
♦ damaged pins No
• Connect all the SJB connectors and make sure The concern may have been caused by a loose or
they seat correctly. corroded connector. CLEAR the DTCs. REPEAT
• Operate the system and verify the concern is the self-test.
still present.


Manual
Parking, Rear and License Plate Lamps
Special Tool(s)


Flex Probe Kit
times out.
When the SJB receives an input from the headlamp switch indicating a request for the parking lamps, the SJB
energizes the parking lamp relay, which supplies voltage to the exterior lamps.
Parking, Rear and License Plate Lamps 6041

• Headlamp • Smart Junction Box (SJB) fuse 22

switch (15A)
• Bulb(s)
• Wiring, terminals, connectors
• SJB



418-00 .
Symptom Chart
Symptom Chart
Pinpoint Tests
Parking, Rear and License Plate Lamps 6042

Pinpoint Test Q: One Or More Parking, Rear or License Plate Lamps Is Inoperative
Refer to Wiring Diagrams Cell 92 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Parking, Rear and License
Normal Operation
When the headlamp switch is placed in the PARKING LAMPS ON position, the Smart Junction Box (SJB)
provides a ground for the parking lamp relay coil (integrated into the SJB ). When the parking lamp relay is
energized, voltage is routed to the front and rear parking lamps.
• Fuse
• Bulb holder
• SJB
PINPOINT TEST Q: ONE OR MORE PARKING, REAR OR LICENSE PLATE LAMPS IS INOPERATIVE

Q1 DETERMINE IF ALL THE PARKING LAMPS ARE
INOPERATIVE
Yes
• Ignition OFF. VERIFY the SJB fuse 22 (15A) is OK.
• Place the headlamp switch in the PARKING LAMPS If OK, GO to Q6 . If not OK, REFER
ON position. to the Wiring Diagrams Manual to
• Are all the parking lamps inoperative? identify the possible causes of the
circuit short.
No
If all the front parking lamps are
inoperative, GO to Q2 . If all the rear
parking and license plate lamps are
inoperative, GO to Q3 . For all others,
GO to Q4 .
Q2 CHECK THE SJB PARKING LAMP OUTPUT
CIRCUIT FOR AN OPEN (FRONT LAMPS)
Yes
• PLACE the headlamp switch in the OFF position. REMOVE the jumper wire. GO to Q6
• Disconnect: SJB C2280e. .
• Connect a fused jumper wire between the SJB C2280e-1,
circuit CDC34 (WH/OG), harness side and the SJB No
C2280e-6, circuit CLS30 (VT/WH), harness side. REMOVE the jumper wire. REPAIR
circuit CLS30 (VT/WH) for an open.

operation.
• Ignition ON.
• Do the front parking lamps illuminate?
Q3 CHECK THE SJB PARKING LAMP OUTPUT
CIRCUIT FOR AN OPEN (REAR LAMPS)
Yes
• PLACE the headlamp switch in the OFF position. REMOVE the jumper wire. GO to Q6
• Disconnect: SJB C2280d. .
• Connect a fused jumper wire between the positive
battery terminal and the SJB C2280d-20, circuit CLS30 No
(VT/WH), harness side. REMOVE the jumper wire. REPAIR
circuit CLS30 (VT/WH) for an open.
operation.
• Do the rear parking lamps illuminate?

Q4 CHECK FOR VOLTAGE TO THE INOPERATIVE
LAMP
Yes
• PLACE the headlamp switch in the OFF position. GO to Q5 .
• Disconnect: Inoperative Lamp.
• Place the headlamp switch in the PARKING LAMPS No
ON position. REPAIR circuit CLS30 (VT/WH) for
• For Fusion, measure the voltage between the inoperative an open. TEST the system for normal
lamp, harness side and ground as follows: operation.
Inoperative Lamp Connector-Pin Circuit

LH front C1023-2 CLS30
(VT/WH)
RH front C1043-2 CLS30
(VT/WH)
LH front side marker C1443-1 CLS30
(VT/WH)
RH front side marker C1444-1 CLS30
(VT/WH)
LH rear C412-2
6044
CLS30
(VT/WH)
RH rear C415-2 CLS30
(VT/WH)
LH rear side marker C4328-1 CLS30
(VT/WH)
RH rear side marker C4327-1 CLS30
(VT/WH)
LH license plate C452-1 CLS30
(VT/WH)
RH license plate C462-1 CLS30
(VT/WH)
• For MKZ, measure the voltage between the inoperative

lamp, harness side and ground as follows:

LH front C1023-2 CLS30
(VT/WH)
RH front C1043-2 CLS30
(VT/WH)
LH front side marker C1113-1 CLS30
(VT/WH)
RH front side marker C1114-1 CLS30
(VT/WH)
LH rear C419-2 CLS30
(VT/WH)
RH rear C418-2 CLS30
(VT/WH)
LH rear (luggage C414-1 CLS30
compartment lid) (VT/WH)
RH rear (luggage C417-1 CLS30
compartment lid) (VT/WH)
LH license plate C452-1 CLS30
(VT/WH)
RH license plate C462-1 CLS30
(VT/WH)
6045

Q5 CHECK FOR VOLTAGE TO THE INOPERATIVE
LAMP USING THE CONNECTOR GROUND
Yes
• For Fusion, measure the voltage between the inoperative For a Fusion rear lamp, any front or
lamp connector, harness side as follows: license plate lamp, INSTALL a new
bulb holder. TEST the system for
normal operation. For a Fusion rear
side marker, or an MKZ rear lamp,
INSTALL a new lamp assembly.
Inoperative Connector-Pin/ Connector-Pin/ REFER to Rear Lamp Assembly or
Lamp Circuit Circuit Reversing Lamp in this section. TEST
LH front C1023-2 C1023-1 the system for normal operation.
CLS30 (VT/WH) GD123 (BK/GY) No

REPAIR the ground circuit in question
RH front C1043-2 C1043-1 for an open. TEST the system for
normal operation.
CLS30 (VT/WH) GD121 (BK/YE)
LH front side C1443-1 C1443-2
marker
RH front side C1444-1 C1444-2
marker
CLS30 (VT/WH) GD123 (BK/GY)
LH rear C412-2 C412-1

RH rear C415-2 C415-1

LH rear side C4328-1 C4328-3
marker
RH rear side C4327-1 C4327-3
marker
LH license plate C452-1 C452-2

RH license plate C462-1 C462-2
6046
• For MKZ, measure the voltage between the inoperative

lamp connector, harness side as follows:
Inoperative Connector-Pin/ Connector-Pin/

Lamp Circuit Circuit
LH front C1023-2 C1023-1

RH front C1043-2 C1043-1

LH front side C1113-1 C1113-2
marker
RH front side C1114-1 C1114-2
marker
LH rear C419-2 C419-3

RH rear C418-2 C418-3

LH rear (luggage C414-1 C414-3
compartment lid)
RH rear (luggage C417-1 C417-3
compartment lid)
LH license plate C452-1 C452-2

RH license plate C462-1 C462-2
6047

Q6 CHECK FOR CORRECT SJB OPERATION
Yes
♦ damaged pins
Pinpoint Test R: The Parking, Rear Or License Plate Lamps Are On Continuously
Refer to Wiring Diagrams Cell 92 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Parking, Rear and License
Normal Operation
The Smart Junction Box (SJB) monitors the parking lamp request input from the headlamp switch. The SJB
provides a ground for the parking lamp relay coil (integrated into the SJB ) when a request for the parking
lamps is received. When the parking lamp relay is energized, voltage is routed to the front and rear parking
lamps.
• DTC B1578 (Lamp Park Input Circuit Short to Ground) - an on-demand DTC that may set when the
SJB detects a short to ground from the parking lamps on input circuit.

• Headlamp switch
• SJB
PINPOINT TEST R: THE PARKING, REAR OR LICENSE PLATE LAMPS ARE ON CONTINUOUSLY

R1 USE THE RECORDED DTCs FROM THE
SJB SELF-TEST
Yes
• Check the recorded results from the SJB GO to R2 .
self-test.
GO to R4 .

R2 CHECK FOR A VOLTAGE SIGNAL TO

THE HEADLAMP SWITCH
Yes
• Ignition OFF. INSTALL a new headlamp switch. REFER to
• Disconnect: Headlamp Switch C205. Headlamp Switch in this section. CLEAR the DTCs.
• Measure the voltage between the headlamp REPEAT the self-test.
switch C205-2, circuit CLS34 (GY),
GO to R3 .

R3 CHECK CIRCUIT CLS34 (YE/OG) FOR
A SHORT TO GROUND
Yes
• Disconnect: SJB C2280b. GO to R5 .
headlamp switch C205-2, circuit CLS34 No
(GY), harness side and ground. REPAIR circuit CLS34 (GY) for a short to ground.

ohms?
R4 CHECK THE SJB PARKING LAMPS
VOLTAGE
Yes
• Ignition OFF. REPAIR circuit CLS30 (VT/WH) for a short to
• Ignition ON.
• Do the parking lamps continue to No
illuminate? GO to R5 .
R5 CHECK FOR CORRECT SJB
OPERATION
Yes
• Disconnect all the SJB connectors. INSTALL a new SJB . REFER to Section 419-10 .
♦ corrosion
♦ damaged pins No
6049

sure they seat correctly. corroded connector. CLEAR the DTCs. REPEAT
• Operate the system and verify the concern the self-test.
is still present.
6050

Manual
Fog Lamps
Special Tool(s)


Flex Probe Kit
The SJB monitors the headlamp switch position by sending a voltage signal to the headlamp switch. When the
fog lamp switch is engaged, the voltage signal is routed to ground.
The fog lamps can be turned on when the following conditions are met:
• The ignition switch is in the RUN or START position.

• The low beam headlamps or the parking lamps are on.
• The high beams are not on.
When the SJB receives an input from the headlamp switch indicating a request for the fog lamps, the SJB
provides voltage to the fog lamp relay. When the fog lamp relay is energized, voltage is routed to the fog
lamps.
2. Visually inspect the following for obvious signs of electrical damage.
Electrical
Fog Lamps 6051

• Battery Junction Box (BJB) fuse 21 (15A) (fog lamp

relay)
• Bulb(s)
• Headlamp switch



418-00 .
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test S: Both Fog Lamps Are Inoperative
Fog Lamps 6052

Refer to Wiring Diagrams Cell 86 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Fog Lamps for schematic
Normal Operation
The Smart Junction Box (SJB) sends a voltage signal to the headlamp switch to monitor the fog lamp request.
When the fog lamp switch is engaged, the voltage signal is routed to ground.
When the SJB detects the fog lamps on request, the SJB energizes the fog lamp relay (integrated into the SJB
). When the fog lamp relay is energized, voltage is routed to the fog lamps.
• Fuse
• Headlamp switch
• SJB
PINPOINT TEST S: BOTH FOG LAMPS ARE INOPERATIVE

S1 CHECK THE SJB FOG LAMP SWITCH PID
Yes
• Ignition ON. VERIFY the SJB fuse 21 (15A) is OK. If
• Enter the following diagnostic mode on the scan OK, GO to S4 . If not OK, REFER to the
tool: SJB Data Logger. Wiring Diagrams Manual to identify the
• Monitor the SJB fog lamp PID (FOG SW) while possible causes of the circuit short.
engaging the fog lamp switch.
• Does the PID indicate the fog lamp switch is on? No
GO to S2 .
S2 CHECK FOR A VOLTAGE SIGNAL TO THE
HEADLAMP SWITCH
Yes
• Ignition OFF. INSTALL a new headlamp switch. REFER
• Disconnect: Headlamp Switch C205. to Headlamp Switch in this section. TEST
• Measure the voltage between the headlamp switch the system for normal operation.
C205-5, circuit CLF21 (GY/VT), harness side and
ground. No
GO to S3 .
• Ignition ON.


S3 CHECK THE FOG LAMPS ON REQUEST
Yes
• Measure the resistance between the headlamp No
switch C205-5, circuit CLF21 (GY/VT), harness REPAIR circuit CLF21 (GY/VT) for an
side and the SJB C2280b-49, circuit CLF21 open. TEST the system for normal
(GY/VT), harness side. operation.

S4 BYPASS THE SJB
Yes
• Ignition OFF. REMOVE the jumper wire. GO to S5 .
• Connect a fused jumper wire between the SJB No
C2280e-1, circuit CDC34 (WH/OG), harness side REMOVE the jumper wire. REPAIR circuit
and the SJB C2280e-3, circuit CLF12 (BN/YE), CLF12 (BN/YE) for an open. TEST the
harness side. system for normal operation.
• Ignition ON.
• Do the fog lamps illuminate?
S5 CHECK FOR CORRECT SJB OPERATION
Yes
♦ damaged pins
seat correctly. time. The concern may have been caused by
• Operate the system and verify the concern is still a loose or corroded connector.
present.
PINPOINT TEST S: BOTH FOG LAMPS ARE INOPERATIVE 6054

Pinpoint Test T: An Individual Fog Lamp Is Inoperative
Normal Operation
When the fog lamp relay is energized, voltage is routed to the fog lamps. A separate ground circuit is supplied
to each fog lamp.
PINPOINT TEST T: AN INDIVIDUAL FOG LAMP IS INOPERATIVE

T1 CHECK FOR VOLTAGE TO THE FOG LAMP
Yes
• Ignition OFF. REPAIR circuit GD121 (BK/YE)
• Disconnect: Inoperative Fog Lamp. (LH fog lamp) or circuit GD123
• Ignition ON. (BK/GY) (RH fog lamp) for an open.
• Place the headlamp switch in the PARKING LAMPS ON TEST the system for normal
position and engage the fog lamp switch. operation.
• For Fusion, measure the voltage between the LH fog
lamp C152-A, circuit CLF12 (BN/YE), harness side and No
ground; or between the RH fog lamp C162-A, circuit REPAIR circuit CLF12 (BN/YE) for
CLF12 (BN/YE), harness side and ground. an open. TEST the system for normal
operation.
• For MKZ, measure the voltage between the LH fog lamp

C152-1, circuit CLF12 (BN/YE), harness side and
ground; or between the RH fog lamp C162-1, circuit
CLF12 (BN/YE), harness side and ground.

Pinpoint Test U: The Fog Lamps Are On Continuously
Normal Operation
The Smart Junction Box (SJB) sends a voltage signal to the headlamp switch to monitor the fog lamp request.
When the fog lamp switch is engaged, the voltage signal is routed to ground.
When the SJB detects the fog lamps on request, the SJB energizes the fog lamp relay (integrated into the SJB
). When the fog lamp relay is energized, voltage is routed through 2 output circuits from the SJB . One output
is to the fog lamps and the other output is to the headlamp switch (for the fog lamps on indicator).
• DTC B2254 (Front Fog Lamp Switch Failure) - an on-demand DTC that sets when the SJB detects a
short to ground from the fog lamp on input circuit.

• Headlamp switch
• SJB
PINPOINT TEST U: THE FOG LAMPS ARE ON CONTINUOUSLY

U1 CHECK FOR RECORDED SJB DTCs
Yes
• Check the recorded results from the SJB GO to U2 .
self-test.
GO to U4 .
U2 CHECK THE HEADLAMP SWITCH
Yes
• Ignition OFF. GO to U3 .
• Disconnect: Headlamp Switch C205.
• Ignition ON. No
• Enter the following diagnostic mode on the INSTALL a new headlamp switch. REFER to
scan tool: SJB Self-Test. Headlamp Switch in this section. CLEAR the
PINPOINT TEST T: AN INDIVIDUAL FOG LAMP IS INOPERATIVE 6056

• NOTE: Other DTCs will be present with the DTCs. REPEAT the self-test.
headlamp switch disconnected and should be
ignored.
• Repeat the SJB self-test.
• Is DTC B2254 still present?
U3 CHECK THE FOG LAMPS ON REQUEST
Yes
• Disconnect: SJB C2280b. GO to U6 .
• Measure the resistance between the headlamp
switch C205-5, circuit CLF21 (GY/VT), No
harness side and ground. REPAIR circuit CLF21 (GY/VT) for a short to
ground. CLEAR the DTCs. REPEAT the
self-test.

U4 CHECK THE SJB FOG LAMPS OUTPUT
CIRCUIT FOR A SHORT TO VOLTAGE (TO
HEADLAMP SWITCH)
Yes
• Ignition OFF. GO to U5 .
• Disconnect: SJB C2280a.
• Ignition ON. No
• Do the fog lamps continue to illuminate? REPAIR circuit CLF12 (BN/YE) to the
headlamp switch for a short to voltage. TEST the
U5 CHECK THE SJB FOG LAMPS OUTPUT
CIRCUIT FOR A SHORT TO VOLTAGE (TO
THE FOG LAMPS)
Yes
• Ignition OFF. REPAIR circuit CLF12 (BN/YE) for a short to
• Ignition ON.
• Do the fog lamps continue to illuminate? No
GO to U6 .
U6 CHECK FOR CORRECT SJB OPERATION
Yes
• Ignition OFF. INSTALL a new SJB . REFER to Section
• Disconnect all the SJB connectors. 419-10 . TEST the system for normal operation.
• Check for:
♦ corrosion No
♦ damaged pins The system is operating correctly at this time.
♦ pushed-out pins The concern may have been caused by a loose or
• Connect all the SJB connectors and make sure corroded connector. CLEAR any DTCs.
they seat correctly. REPEAT the self-test.
PINPOINT TEST U: THE FOG LAMPS ARE ON CONTINUOUSLY 6057


still present.
Pinpoint Test V: The Fog Lamps On Indicator Is Inoperative
Normal Operation
When the Smart Junction Box (SJB) detects the fog lamps on request, the SJB energizes the fog lamp relay
(integrated into the SJB ). When the fog lamp relay is energized, voltage is routed through 2 output circuits
from the SJB . One output is to the fog lamps and the other output is to the headlamp switch (for the fog
lamps on indicator).

• Headlamp switch
• SJB
PINPOINT TEST V: THE FOG LAMPS ON INDICATOR IS INOPERATIVE

V1 CHECK THE HEADLAMP SWITCH
Yes
• Ignition OFF. INSTALL a new headlamp switch. REFER
• Disconnect: Headlamp Switch C205. to Headlamp Switch in this section. TEST
• Select the SJB fog lamps (FOG_LMP) active GO to V2 .
command. Command the fog lamps on.
• NOTE: Make sure the fog lamps are illuminated
when taking a reading.
• Measure the voltage between the headlamp switch
C205-10, circuit CLF12 (BN/YE), harness side and
ground.


V2 CHECK THE SJB FOG LAMPS OUTPUT
CIRCUIT FOR AN OPEN
Yes
• Measure the resistance between the headlamp No
switch C205-10, circuit CLF12 (BN/YE), harness REPAIR circuit CLF12 (BN/YE) for an
side and the SJB C2280a-6, circuit CLF12 open. CLEAR the DTCs. REPEAT the
(BN/YE), harness side. self-test.

V3 CHECK FOR CORRECT SJB OPERATION
Yes
♦ damaged pins
• Operate the system and verify the concern is still a loose or corroded connector. CLEAR any
PINPOINT TEST V: THE FOG LAMPS ON INDICATOR IS INOPERATIVE 6059

PINPOINT TEST V: THE FOG LAMPS ON INDICATOR IS INOPERATIVE 6060


Manual
Reversing Lamps
Special Tool(s)


Flex Probe Kit
For vehicles equipped with an automatic transaxle, the PCM (2.5L or 3.0L engine) or the Transmission
Control Module (TCM) (3.5L engine) controls the coil ground side of the reversing lamps relay. When the
vehicle is in reverse, the PCM or TCM energizes the reversing lamps relay to provide voltage to the reversing
lamps.
For vehicles equipped with a manual transaxle, the reversing lamp switch controls the coil ground side of the
reversing lamps relay. When the vehicle is in reverse, the reversing lamp switch contacts close to ground,
energizing the reversing lamps relay to provide voltage to the reversing lamps.
• Reversing lamp switch (manual • Battery Junction Box (BJB) fuse 47

transaxle) (10A)
• Bulb(s)
• Reversing lamps relay
Reversing Lamps 6061




418-00 .
8. Clear the continuous DTCs and carry out the self-test diagnostics for the PCM or TCM .
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test W: Both Reversing Lamps Are Inoperative
Refer to Wiring Diagrams Cell 11 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Fuse and Relay Information
Refer to Wiring Diagrams Cell 93 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Reversing Lamps for
Reversing Lamps 6062

Normal Operation
Voltage is supplied from the Battery Junction Box (BJB) fuse 47 (10A) to the coil and switched sides of the
reversing lamps relay. When the reversing lamps relay is energized, voltage is routed to the reversing lamps.
Automatic Transaxle
The PCM (2.5L or 3.0L engines) or the Transmission Control Module (TCM) (3.5L engine) monitors the
transaxle gear status. When the PCM detects the transaxle in REVERSE (R), the PCM or TCM provides
ground for the reversing lamps relay coil.
Manual Transaxle
The reversing lamp switch controls the coil ground side of the reversing lamps relay. When the transaxle is in
REVERSE (R), the reversing lamp switch contacts close, completing the path to ground for the reversing
lamps relay coil.
• DTC P1910 (Reverse Lamp Control Circuit/Open) - sets when the PCM detects no voltage on the
reversing lamp relay coil ground control circuit (if the coil voltage supply circuit or the coil ground
control circuit is open).
• Fuse
• Reversing lamp switch
• PCM
• TCM
PINPOINT TEST W: BOTH REVERSING LAMPS ARE INOPERATIVE
Result / Action
Test Step
to Take
W1 CHECK THE
REVERSING LAMPS RELAY
Yes
• Ignition OFF. REMOVE the
• Disconnect: Reversing known good
Lamps Relay. relay.
• Ignition ON. INSTALL a
• Substitute a known good new reversing
relay and recheck the lamps relay.
reversing lamps operation. TEST the
• Do the reversing lamps system for
operate correctly? normal
operation.
No

REMOVE the
known good
relay. GO to
W2 .
Yes
• Ignition ON. GO to W3 .
• Measure the voltage
between the reversing No
lamps relay pin 1, VERIFY the BJB
circuit CBK03 (GY), fuse 47 (10A) is
BJB face side and OK. If OK,
ground. REPAIR circuit
W2 CHECK FOR VOLTAGE CBK03 (GY) for
TO THE REVERSING LAMPS an open. TEST
RELAY COIL the system for
normal operation.
If not OK,
REFER to the
Wiring Diagrams
Manual to identify
the possible
• Is the voltage greater causes of the
than 10 volts? circuit short.
W3 CHECK FOR VOLTAGE
TO THE REVERSING LAMPS
RELAY SWITCH
Yes
• Measure the voltage GO to W4 .
between the reversing
lamps relay pin 3, circuit No
CBK03 (GY), BJB face REPAIR circuit
side and ground. CBK03 (GY)
for an open.
TEST the
system for
normal
operation.
• Is the voltage greater

than 10 volts?
W4 BYPASS THE
Yes
• Connect a fused jumper REMOVE the
wire between the reversing jumper wire.
lamps relay pin 3, circuit For vehicles
CBK03 (GY), BJB face with a manual
side and the reversing transaxle, GO
lamps relay pin 5, circuit to W5 . For
PINPOINT TEST W: BOTH REVERSING LAMPS ARE INOPERATIVE 6064

CLS10 (GN/BN), BJB vehicles with an

face side. automatic
transaxle, GO
to W7 .
No
REMOVE the
jumper wire.
REPAIR circuit
CLS10
(GN/BN) for an
open. TEST the
• Do the reversing lamps
system for
illuminate?
normal
operation.
TO THE REVERSING LAMP
SWITCH
Yes
• Ignition OFF. GO to W6 .
• Connect: Reversing
Lamps Relay. No
• Disconnect: Reversing REPAIR circuit
Lamp Switch C169. CLS28
• Ignition ON. (BU/WH) for
• Measure the voltage an open. TEST
between the reversing the system for
lamp switch C169-1, normal
circuit CLS28 (BU/WH), operation.

than 10 volts?
TO THE REVERSING LAMP
SWITCH USING THE
CONNECTOR GROUND
Yes
• Measure the voltage INSTALL a
between the reversing new reversing
lamp switch C169-1, lamp switch.
circuit CLS28 (BU/WH), REFER to
harness side and the Reversing
reversing lamp switch Lamp Switch in
C169-2, circuit GD121 this section.

(BK/YE), harness side. TEST the

system for
normal
operation.
No
REPAIR circuit
GD121
(BK/YE) for an
open. TEST the
system for
normal
than 10 volts?
operation.
W7 CHECK FOR PCM OR
TCM TR SENSOR DTCs
FROM THE SELF-TEST
Yes
• Review the DTCs from the REFER to
PCM (2.5L or 3.0L Section
engine) or the TCM (3.5L 307-01A ,
engine) Key ON Engine Section
OFF (KOEO) self-test. 307-01B or
• Are any TR sensor DTCs Section
present? 307-01C .
No
GO to W8 .
W8 CHECK THE
COIL GROUND
CONTROLLED CIRCUIT FOR
A SHORT TO VOLTAGE
Yes
• Ignition OFF. REPAIR circuit
• Disconnect: PCM C175t CLS28
(2.5L or 3.0L Engine). (BU/WH) for a
• Disconnect: TCM C1533 short to voltage.
(3.5L Engine). CLEAR the
• Ignition ON. DTCs.
• For Hybrid vehicles, REPEAT the
measure the voltage self-test.
between the PCM
C175t-34, circuit CLS28 No
(BU/WH), harness side GO to W9 .
and ground.

• For non-Hybrid vehicles

with a 2.5L or 3.0L
engine, measure the
voltage between the PCM
C175t-33, circuit CLS28
(BU/WH), harness side
and ground.
• For vehicles with a 3.5L

engine, measure the
voltage between the TCM
C1533-13, circuit CLS28
and ground.

TO THE PCM OR THE TCM
WITH THE REVERSING
LAMP RELAY CONNECTED
Yes
• Ignition OFF. For vehicles
• Connect: Reversing with a 3.5L
Lamps Relay. engine, GO to
• Ignition ON. W10 .
• For Hybrid vehicles,
measure the voltage For all other
between the PCM vehicles, GO to
C175t-34, circuit CLS28 W11 .

and ground. No
REPAIR circuit
CLS28
(BU/WH) for
an open.
CLEAR the
DTCs.
REPEAT the
self-test.
• For non-Hybrid vehicles

with a 2.5L or 3.0L
engine, measure the
voltage between the PCM
C175t-33, circuit CLS28
and ground.
• For vehicles with a 3.5L

engine, measure the
voltage between the TCM
C1533-13, circuit CLS28
and ground.

than 10 volts?
W10 CHECK FOR CORRECT
TCM OPERATION
Yes
• Disconnect the TCM INSTALL a
connector. new TCM .
• Check for: REFER to
♦ corrosion Section
♦ damaged pins 307-01A .
♦ pushed-out pins TEST the

• Connect the TCM system for

connector and make sure it normal
seats correctly. operation.
verify the concern is still No
present. The system is
• Is the concern still operating
present? correctly at this
time. The
concern may
have been
caused by a
loose or
corroded
connector.
W11 CHECK FOR CORRECT
PCM OPERATION
Yes
• Disconnect all the PCM INSTALL a
connectors. new PCM.
• Check for: REFER to
♦ corrosion Section
♦ damaged pins 303-14A ,
♦ pushed-out pins Section
• Connect all the PCM 303-14B ,
connectors and make sure Section
they seat correctly. 303-14C or
• Operate the system and Section
verify the concern is still 303-14D .
present. TEST the
• Is the concern still system for
present? normal
operation.
No
The system is
operating
correctly at this
time. The
concern may
have been
caused by a
loose or
corroded
connector.
Pinpoint Test X: The Individual Reversing Lamp Is Inoperative
When the reversing lamps relay is energized, voltage is routed to the reversing lamps.


• Bulb holder
PINPOINT TEST X: THE INDIVIDUAL REVERSING LAMP IS INOPERATIVE
Result / Action to
Test Step
Take
X1 CHECK FOR VOLTAGE TO THE REVERSING LAMP
Yes
• Ignition OFF. GO to X2 .
• Disconnect: Inoperative Reversing Lamp.
• Apply the parking brake. No
• Ignition ON. REPAIR circuit CLS10
• Select REVERSE. (GN/BN) for an open.
• For Fusion, measure the voltage between the LH rear lamp C487-1, TEST the system for
circuit CLS10 (GN/BN), harness side and ground, or between the RH normal operation.
rear lamp C488-1, circuit CLS10 (GN/BN), harness side and ground.
• For MKZ, measure the voltage between the LH rear lamp C451-1,
circuit CLS10 (GN/BN), harness side and ground, or between the RH
rear lamp C461-1, circuit CLS10 (GN/BN), harness side and ground.

X2 CHECK FOR VOLTAGE TO THE REVERSING LAMP USING
PINPOINT TEST X: THE INDIVIDUAL REVERSING LAMP IS INOPERATIVE 6070

• For Fusion, measure the voltage between the LH rear lamp C487-1, Yes
circuit CLS10 (GN/BN), harness side and the LH rear lamp C487-2, INSTALL a new bulb
circuit GD171 (BK/GY), harness side, or between the RH rear lamp holder. TEST the
C488-1, circuit CLS10 (GN/BN), harness side and the RH rear lamp system for normal
C488-2, circuit GD171 (BK/GY), harness side. operation.
No
(BK/GY) for an open.
TEST the system for
normal operation.
• For MKZ, measure the voltage between the LH rear lamp C451-1,
circuit CLS10 (GN/BN), harness side and the LH rear lamp C451-2,
circuit GD171 (BK/GY), harness side, or between the RH rear lamp
C461-1, circuit CLS10 (GN/BN), harness side and the RH rear lamp
C461-2, circuit GD171 (BK/GY), harness side.
Pinpoint Test Y: The Reversing Lamps Are On Continuously
Normal Operation
Voltage is supplied from the Battery Junction Box (BJB) fuse 47 (10A) to the coil and switched sides of the
reversing lamps relay. When the reversing lamps relay is energized, voltage is routed to the reversing lamps.
Automatic Transaxle
The PCM (2.5L or 3.0L engines) or the Transmission Control Module (TCM) (3.5L engine) monitors the
transaxle gear status. When the PCM detects the transaxle is in REVERSE (R), the PCM or TCM provides
ground for the reversing lamps relay coil.
Manual Transaxle
The reversing lamp switch controls the coil ground side of the reversing lamps relay. When the transaxle is in
REVERSE (R), the reversing lamp switch contacts close, completing the path to ground for the reversing
lamps relay coil.

• DTC P1910 (Reverse Lamp Control Circuit/Open) - sets when the PCM detects no voltage on the
reversing lamp relay coil ground control circuit (if the coil ground control circuit is short to ground).

• Reversing lamp switch
• Auto-dimming interior mirror
• PCM
• TCM
PINPOINT TEST Y: THE REVERSING LAMPS ARE ON CONTINUOUSLY

Y1 CHECK THE REVERSING
LAMPS RELAY
Yes
• Ignition OFF. REMOVE the known good relay. GO to Y2 .
• Substitute a known good relay.
• Ignition ON. No
• Do the reversing lamps REMOVE the known good relay. INSTALL a new reversing
continue to illuminate? lamps relay. TEST the system for normal operation.
LAMPS RELAY OUTPUT
Yes
• Ignition OFF. If equipped with an auto-dimming interior mirror, GO to Y3 .
• Disconnect: Reversing Lamps If not equipped with an auto-dimming interior mirror,
Relay. REPAIR circuit CLS10 (GN/BN) for a short to voltage. TEST
continue to illuminate? No
For vehicles with a manual transaxle, GO to Y4 . For vehicles
with an automatic transaxle, GO to Y5 .
Y3 ISOLATE THE SHORT TO
VOLTAGE
Yes
• Ignition OFF. REPAIR circuit CLS10 (GN/BN) for a short to voltage. TEST
• Disconnect: Auto-Dimming the system for normal operation.
Interior Mirror C911 or C9039.
• Ignition ON. No
• Do the reversing lamps INSTALL a new auto-dimming interior mirror. REFER to
continue to illuminate? Section 501-09 . TEST the system for normal operation.
LAMP SWITCH
Yes
• Ignition OFF. REPAIR circuit CLS28 (BU/WH) for a short to ground. TEST

• Connect: Reversing Lamps the system for normal operation.

Relay.
• Disconnect: Reversing Lamp No
Switch C169. INSTALL a new reversing lamp switch. REFER to Reversing
• Ignition ON. Lamp Switch in this section. TEST the system for normal
• Do the reversing lamps operation.
Y5 CHECK FOR PCM OR TCM TR
SENSOR DTCs FROM THE
SELF-TEST
Yes
• Review the DTCs from the PCM REFER to Section 307-01A , Section 307-01B or Section
(2.5L or 3.0L engine) or the 307-01C .
TCM (3.5L engine) Key ON
Engine OFF (KOEO) self-test. No
• Are any TR sensor DTCs GO to Y6 .
present?
LAMPS RELAY CONTROL
CIRCUIT FOR A SHORT TO
GROUND
Yes
• Ignition OFF. REPAIR circuit CLS28 (BU/WH) for a short to ground. TEST
• Connect: Reversing Lamps the system for normal operation.
Relay.
• Disconnect: PCM C175t (2.5L or No
3.0L Engine, ). For vehicles with a 3.5L engine, GO to Y7 . For all other
• Disconnect: TCM C1533 (3.5L vehicles, GO to Y8 .
Engine).
• Ignition ON.
Y7 CHECK FOR CORRECT TCM
OPERATION
Yes
• Disconnect the TCM connector. INSTALL a new TCM . REFER to Section 307-01A . TEST
• Check for: the system for normal operation.
♦ corrosion
♦ damaged pins No
♦ pushed-out pins The system is operating correctly at this time. The concern
• Connect the TCM connector and may have been caused by a loose or corroded connector.
make sure it seats correctly.
Y8 CHECK FOR CORRECT PCM
OPERATION
Yes
• Disconnect the PCM connector. INSTALL a new PCM. REFER to Section 303-14A , Section
• Check for: 303-14B or Section 303-14D . TEST the system for normal
♦ damaged pins
PINPOINT TEST Y: THE REVERSING LAMPS ARE ON CONTINUOUSLY 6073

• Connect the PCM connector and The system is operating correctly at this time. The concern
• Operate the system and verify the CLEAR any DTCs. REPEAT the self-test.
PINPOINT TEST Y: THE REVERSING LAMPS ARE ON CONTINUOUSLY 6074


Manual
Daytime Running Lamps (DRL)
Special Tool(s)

The SJB controls the Daytime Running Lamps (DRL) by using various inputs to determine whether or not the
DRL should be illuminated. These inputs include:
• Ignition switch position

• Headlamp switch position
• Headlamps on or off
• Transmission gear selection (automatic transaxle)
• Parking brake applied or released (manual transaxle)
When the DRL is active, the SJB provides a pulse-width modulated voltage to the low beam headlamps. This
illuminates the headlamps at a reduced intensity.
The DRL is not a programmable parameter for this vehicle.

Daytime Running Lamps (DRL) 6075


• Verify the ignition key is in the RUN position.

418-00 .
7. Clear the continuous DTCs and carry out the self-test diagnostics for the PCM, the SJB , and the IPC .
8. If the DTCs retrieved are related to the concern, refer to the Powertrain Control/Emissions Diagnosis
(PC/ED) manual or the Diagnostic Trouble Code (DTC) Chart in Section 419-10 .
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test Z: The Daytime Running Lamps (DRL) Are Inoperative
Normal Operation
When the ignition switch is in the RUN position, the headlamps are not on, the transaxle is not in PARK (P)
(automatic transaxle) or the parking brake is not applied (manual transaxle), the Smart Junction Box (SJB)
provides a pulse-width modulated voltage to the low beam headlamps. This illuminates the headlamps at a
reduced intensity.
• Exterior lighting system input/output

• Ignition switch input
• Transaxle gear input (automatic transaxle)
• Parking brake switch input (manual transaxle)
• SJB
PINPOINT TEST Z: THE DRL ARE INOPERATIVE

Z1 VERIFY THE DRL OPERATION
Yes
• Ignition ON. The system is operating correctly.
• Place the headlamp switch in the OFF position. INFORM the customer of the

• If equipped with an automatic transaxle, place the gear conditions required for the DRL to
selector lever in any gear other than PARK (P). operate correctly.
• If equipped with a manual transaxle, release the parking
brake. No
• Do the DRL illuminate? GO to Z2 .
Z2 CHECK THE OPERATION OF THE HEADLAMPS
(VEHICLES WITH HALOGEN HEADLAMPS) OR FOG
LAMPS (VEHICLES WITH HID HEADLAMPS)
Yes
• Place the headlamp switch in the HEADLAMPS ON GO to Z3 .
position (and engage the fog lamp switch for vehicles with
HID headlamps) and observe the headlamps/fog lamps. No
• Do the headlamps/fog lamps operate correctly? REFER to Headlamps or Fog Lamps
in this section.
Z3 CHECK THE IGNITION SWITCH INPUT
Yes
• Place the headlamp switch in the OFF position. For vehicles with an automatic
• Enter the following diagnostic mode on the scan tool: SJB transaxle, GO to Z4 .
DataLogger.
• Monitor the SJB ignition switch PIDs (IGN_A_ECU, For vehicles with a manual transaxle,
IGN_O_ECU, IGN_R_ECU, IGN_S_ECU) while cycling GO to Z5 .
the ignition switch through all its positions.
• Does the PID agree with the ignition switch positions? No
REFER to Section 211-05 to
diagnose the ignition switch input.
Z4 CHECK THE TRANSAXLE GEAR INPUT
Yes
• Ignition ON. INSTALL a new SJB . REFER to
• Enter the following diagnostic mode on the scan tool: Section 419-10 . TEST the system
PCM DataLogger. for normal operation.
• Monitor the PCM transmission gear status PID (TR) while
placing the gear selector lever through all its positions. No
• Does the PID agree with the gear selection? REFER to Section 307-01A , Section
307-01B or Section 307-01C to
diagnose the digital Transmission
Range (TR) sensor input.
Z5 CHECK THE BRAKE WARNING INDICATOR
OPERATION
Yes
• Ignition ON. INSTALL a new SJB . REFER to
• Apply and release the parking brake while observing the Section 419-10 . TEST the system
brake warning indicator. for normal operation.
• Does the brake warning indicator operate correctly?
No
REFER to Section 413-01 to
diagnose the brake warning indicator.
PINPOINT TEST Z: THE DRL ARE INOPERATIVE 6077

PINPOINT TEST Z: THE DRL ARE INOPERATIVE 6078


Manual
Adaptive Headlighting
Special Tool(s)


Flex Probe Kit
The Headlamp Control Module (HCM) receives information from the communication network such as vehicle
speed, steering wheel angle and headlamps on status. Based on the information received, the HCM determines
if the headlamps need to be angled left or right as well as the degree of angle.
The HCM does not operate the adaptive headlamps until the vehicle speed is above 5 km/h (3 mph).
When the ignition is placed in the RUN/START position, the HCM runs an initialization check to determine
the straight-ahead position of the headlamps. If the HCM does not receive the required information over the
communication network or determines that there is a fault with the circuitry to the sensors or control motors, it
defaults the headlamps to the straight-ahead position and sets DTC(s).
• Headlamp • Smart Junction Box (SJB) fuse 42
assembly (10A)
• Headlamp Control Module
(HCM)
Adaptive Headlighting 6079




418-00 .
8. Clear the continuous DTCs and carry out the self-test diagnostics for the HCM .
9. If the DTCs retrieved are related to the concern, go to Diagnostic Trouble Code (DTC) Chart in this
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test AA: DTC B1A98:88
• DTC B1A98:88 (LIN Bus Circuit #1: Bus off) - sets continuous and on-demand by the Headlamp
Control Module (HCM) if communication is lost to the headlamps due to a circuit fault on the
communication circuit between the HCM and the headlamps.

Adaptive Headlighting 6080

• HCM
PINPOINT TEST AA: DTC B1A98:88

AA1 ISOLATE THE LH HEADLAMP ASSEMBLY AS
THE CAUSE OF THE DTC
Yes
• Disconnect: LH Headlamp Assembly C1021.
• Ignition ON. No
• Enter the following diagnostic mode on the scan tool: INSTALL a new LH headlamp assembly.
HCM Self-Test. REFER to Headlamp Assembly in this
• NOTE: Other DTCs can be present with the section. CLEAR the DTCs. REPEAT the
headlamp assembly disconnected and should be self-test.
ignored.
• Clear the DTCs and repeat the HCM self-test.
• Is DTC B1A98:88 still present?
AA2 ISOLATE THE RH HEADLAMP ASSEMBLY AS
THE CAUSE OF THE DTC
Yes
• Disconnect: RH Headlamp Assembly C1041.
• Ignition ON. No
• Enter the following diagnostic mode on the scan tool: INSTALL a new RH headlamp assembly.
HCM Self-Test. REFER to Headlamp Assembly in this
• NOTE: Other DTCs can be present with the section. CLEAR the DTCs. REPEAT the
headlamp assembly disconnected and should be self-test.
ignored.
• Clear the DTCs and repeat the HCM self-test.
• Is DTC B1A98:88 still present?
AA3 CHECK THE COMMUNICATION CIRCUITS
TO THE HEADLAMPS FOR A SHORT TO VOLTAGE
Yes
• Ignition OFF. REPAIR circuit VLF32 (YE) (LH
• Disconnect: HCM C1600. headlamp) or circuit VLF33 (BU) (RH
• Ignition ON. headlamp) for a short to voltage. CLEAR
• Measure the voltage between the HCM C1600-17, the DTCs. REPEAT the self-test.
circuit VLF32 (YE), harness side, and ground; and
the HCM C1600-18, circuit VLF33 (BU), harness No
side, and ground. GO to AA4 .
PINPOINT TEST AA: DTC B1A98:88 6081


AA4 CHECK THE COMMUNICATION CIRCUITS
TO THE HEADLAMPS FOR A SHORT TO GROUND
Yes
• Measure the resistance between the HCM C1600-17,
circuit VLF32 (YE), harness side, and ground; and No
the HCM C1600-18, circuit VLF33 (BU), harness REPAIR circuit VLF32 (YE) (LH
side, and ground. headlamp) or circuit VLF33 (BU) (RH
headlamp) for a short to ground. CLEAR

AA5 CHECK FOR CORRECT HCM OPERATION
Yes
• Disconnect all the HCM connectors. INSTALL a new HCM . REFER to
• Check for: Headlamp Control Module (HCM) in this
♦ pushed-out pins
• Connect all the HCM connectors and make sure they No
seat correctly. The system is operating correctly at this
present. by a loose or corroded connector.
Pinpoint Test AB: DTC B1D64:87, B1D65:87
• DTC B1D64:87 (Left Headlamp Swivelling Motor: Missing Message) - sets continuous and
on-demand in the Headlamp Control Module (HCM) if data messages from the LH headlamp are
missing.
• DTC B1D65:87 (Right Headlamp Swivelling Motor: Missing Message) - sets continuous and
on-demand in the HCM if data messages from the RH headlamp are missing.
This pinpoint test is intended to diae the following:

• HCM
PINPOINT TEST AB: DTC B1D64:87, B1D65:87
PINPOINT TEST AB: DTC B1D64:87, B1D65:87 6082

AB1 CHECK FOR VOLTAGE TO THE HEADLAMP

Yes
• Disconnect: LH Headlamp Assembly C1021 (DTC B1D64:87).
• Disconnect: RH Headlamp Assembly C1041 (DTC B1D65:87). No
• Ignition ON. REPAIR circuit CBP42 (GN)
• Measure the voltage between the LH headlamp C1021-5, for an open. CLEAR the DTCs.
circuit CBP42 (GN), harness side and ground; or between the REPEAT the self-test.
RH headlamp C1041-5, circuit CBP42 (GN), harness side and
ground.

AB2 CHECK FOR VOLTAGE TO THE HEADLAMP USING
Yes
• Measure the voltage between the LH headlamp C1021-5, GO to AB3 .
circuit CBP42 (GN), harness side and the LH headlamp
C1021-3, circuit GD121 (BK/YE), harness side; or between the No
RH headlamp C1041-5, circuit CBP42 (GN), harness side and REPAIR circuit GD121
the RH headlamp C1041-3, circuit GD123 (BK/GY), harness (BK/YE) (LH headlamp) or
side. circuit GD123 (BK/GY) (RH
headlamp) for an open. CLEAR
self-test.

AB3 CHECK THE COMMUNICATION CIRCUIT BETWEEN
THE HCM AND THE HEADLAMP FOR AN OPEN
Yes
• Disconnect: HCM C1600.
• For the LH headlamp, measure the resistance between the HCM No
C1600-17, circuit VLF32 (YE), harness side and the LH REPAIR circuit VLF32 (YE)
headlamp C1021-2, circuit VLF32 (YE), harness side. (LH headlamp) or circuit
VLF33 (BU) (RH headlamp)
PINPOINT TEST AB: DTC B1D64:87, B1D65:87 6083

• For the RH headlamp, measure the resistance between the

HCM C1600-18, circuit VLF33 (BU), harness side and the RH
headlamp C1041-2, circuit VLF33 (BU), harness side.

AB4 CHECK FOR CORRECT HCM OPERATION
Yes
• Disconnect all the HCM connectors. INSTALL a new HCM .
• Check for: REFER to Headlamp Control
♦ corrosion Module (HCM) in this section.
• Connect all the HCM connectors and make sure they seat
correctly. No
connector.
Pinpoint Test AC: DTC U0100:87
• DTC U0100:87 (Lost Communication With ECM/PCM "A": Missing Message) - sets continuous in
the Headlamp Control Module (HCM) if data messages received from the PCM over the High Speed
Controller Area Network (HS-CAN) are missing. For a complete list of all network messages, refer to
Section 418-00 .
• HCM
• PCM
PINPOINT TEST AC: DTC U0100:87
NOTE: If new modules were installed prior to the DTC being set, the module configuration may be
incorrectly set during the Programmable Module Installation (PMI) or the PMI may not have been carried out.
PINPOINT TEST AC: DTC U0100:87 6084


AC1 VERIFY THAT THE SCAN TOOL
CAN COMMUNICATE WITH THE PCM
Yes
• Ignition ON. GO to AC2 .
• Check that a vehicle session can be
established using the scan tool. No
• Can a vehicle session be REFER to Section 418-00 to diagnose no communication
established? with the PCM.
AC2 CHECK THE IPC CONTINUOUS
MEMORY DTCs
Yes
• Enter the following diagnostic mode GO to AC3 .
on the scan tool: HCM Self-Test.
• Clear the DTCs. Repeat the HCM No
self-test. The system is operating correctly at this time. The DTC
• Is DTC U0100:87 retrieved again? may have been set due to high network traffic or an
AC3 RETRIEVE THE RECORDED
DTCs FROM THE HCM SELF-TEST
Yes
• Check for recorded DTCs from the For DTC U3003:16, GO to Pinpoint Test AH .
HCM self-test.
• Is DTC U3003:16 or DTC U3003:17 For DTC U3003:17 GO to Pinpoint Test AI .
recorded?
No
GO to AC4 .
AC4 CHECK FOR DTC U0100 SET IN
OTHER MODULES
Yes
• Enter the following diagnostic mode INSTALL a new PCM. REFER to Section 303-14A ,
on the scan tool: Self-Test. Section 303-14B , Section 303-14C or Section 303-14D .
• Retrieve the continuous memory TEST the system for normal operation.
DTCs from all modules.
• Is DTC U0100 set in the Instrument No
Panel Cluster (IPC) or the INSTALL a new HCM . REFER to Headlamp Control
Restraints Control Module (RCM)? Module (HCM) in this section. TEST the system for
normal operation.
Pinpoint Test AD: DTC U0101:87
• DTC U0101:87 (Lost Communication With TCM : No Sub-Type Information) - sets continuous in the
Headlamp Control Module (HCM) if data messages received from the Transmission Control dule
(TCM) over the High Speed Controller Area Network (HS-CAN) are missing. For a complete list of
all network messages, refer to Section 418-00 .
• HCM
• TCM
PINPOINT TEST AC: DTC U0100:87 6085

PINPOINT TEST AD: DTC U0101:87
NOTE: If other new modules were installed prior to the DTC being set, the module configuration may be

AD1 VERIFY THE CUSTOMER
CONCERN
Yes
symptom present. No
• Is an observable symptom present? The system is operating normally at this time. The DTC
may have been set due to high network traffic or an
AD2 CHECK THE COMMUNICATION
NETWORK
Yes
• Enter the following diagnostic mode on GO to AD3 .
the scan tool: Network Test.
• Does the TCM pass the network test? REFER to Section 418-00 .
AD3 CHECK THE RECORDED DTCs
FROM THE HCM SELF-TEST
Yes
• Check for recorded DTCs from the IPC For DTC U3003:16, GO to Pinpoint Test AH .
self-test.
recorded?
No
GO to AD4 .
AD4 RECHECK THE HCM DTCs
Yes
• Enter the following diagnostic mode on INSTALL a new TCM . REFER to Section 307-01A .
the scan tool: HCM Self-Test. CLEAR the DTCs. REPEAT the self-test.
• Clear the DTCs. Repeat the IPC
self-test. If DTC U0101:87 is still present, INSTALL a new
• Is DTC U0101:87 still present? HCM . REFER to Headlamp Control Module (HCM) in
No
The system is operating correctly at this time. The DTC
Pinpoint Test AE: DTC U0121:87
Normal Operation
• DTC U0121:87 (Lost Communication With Anti-Lock Brake System (ABS) Control Module:
PINPOINT TEST AD: DTC U0101:87 6086

Missing Message) - sets continuous by the Headlamp Control Module (HCM) if data messages
received from the ABS module over the High Speed Controller Area Network (HS-CAN) are missing.
For a complete list of all network messages, refer to Section 418-00 .
• HCM
• ABS module
PINPOINT TEST AE: DTC U0121:87

AE1 VERIFY THE CUSTOMER
CONCERN
Yes
symptom present. No
• Is an observable symptom The system is operating normally at this time. The DTC may
present? have been set due to high network traffic or an intermittent
fault condition.
AE2 CHECK THE
COMMUNICATION NETWORK
Yes
• Enter the following diagnostic GO to AE3 .
mode on the scan tool: Network
Test. No
• Does the ABS module pass the
network test?
AE3 RETRIEVE THE RECORDED
DTCs FROM THE HCM SELF-TEST
Yes
HCM self-test.
• Is DTC U3003:16 or DTC For DTC U3003:17 GO to Pinpoint Test AI .
U3003:17 recorded?
No
GO to AE4 .
AE4 RECHECK THE HCM DTCs
Yes
• Enter the following diagnostic INSTALL a new ABS module. REFER to Section 206-09 .
mode on the scan tool: HCM CLEAR the DTCs. REPEAT the self-test.
Self-Test.
• Clear the DTCs. Repeat the HCM If DTC U0121:87 is still present, INSTALL a new HCM .
self-test. REFER to Headlamp Control Module (HCM) in this section.
• Is DTC U0121:87 still present? TEST the system for normal operation.
PINPOINT TEST AE: DTC U0121:87 6087

No
The system is operating correctly at this time. The DTC may
have been set due to high network traffic or an intermittent
fault condition.
Pinpoint Test AF: DTC U0126:87
• DTC U0126:87 (Lost Communication With Steering Wheel Angle Sensor Module: Missing Message)
- sets continuous in the Headlamp Control Module (HCM) if data messages received from the Power
Steering Control Module (PSCM) over the High Speed Controller Area Network (HS-CAN) are
missing. For a complete list of all network messages, refer to Section 418-00 .
The PSCM is integrated into the steering gear.
• HCM
• PSCM
PINPOINT TEST AF: U0126:87
If new modules were installed prior to the DTC being set, the module configuration may be incorrectly set
during the Programmable Module Installation (PMI) or the PMI may not have been carried out.

AF1 VERIFY THE CUSTOMER
CONCERN
Yes
symptom present. No
AF2 CHECK THE COMMUNICATION
NETWORK
Yes
• Enter the following diagnostic mode on GO to AF3 .
• Does the PSCM pass the network test? REFER to Section 418-00 .
AF3 RETRIEVE THE RECORDED DTCs
FROM THE HCM SELF-TEST
Yes
HCM self-test.
recorded?
No
PINPOINT TEST AF: U0126:87 6088

GO to AF4 .
AF4 RECHECK THE HCM DTCs
Yes
• Enter the following diagnostic mode on INSTALL a new steering gear. REFER to Section
the scan tool: HCM Self-Test. 211-02 . CLEAR the DTCs. REPEAT the self-test.
• Clear the DTCs. Repeat the HCM
• Is DTC U0126:87 still present? HCM . REFER to Headlamp Control Module (HCM)
in this section. TEST the system for normal operation.
No
Pinpoint Test AG: DTC U0155:87
• DTC U0155:87 (Lost Communication With Instrument Panel Cluster (IPC) Control Module: No Sub
Type Information) - sets continuous by the HCM if data messages (ignition switch status, headlamps
on status) received from the IPC over the HS-CAN are missing. For a complete list of all network
The Smart Junction Box (SJB) communicates the headlamps on status to the IPC over the Medium Speed
Controller Area Network (MS-CAN). The IPC acts as a gateway module and relays the information through
the High Speed Controller Area Network (HS-CAN) to the HCM .
• HCM
• IPC
PINPOINT TEST AG: U0155:87

AG1 VERIFY THE CUSTOMER
CONCERN
Yes
symptom present. No
AG2 CHECK THE COMMUNICATION
NETWORK
Yes
GO to AG3 .
PINPOINT TEST AG: U0155:87 6089


the scan tool: Network Test. No
• Does the IPC pass the network test?
AG3 RETRIEVE THE RECORDED DTCs
Yes
HCM self-test.
recorded?
No
GO to AG4 .
AG4 RECHECK THE HCM DTCs
Yes
• Enter the following diagnostic mode on INSTALL a new IPC . REFER to Section 413-01 .
the scan tool: HCM Self-Test. CLEAR the DTCs. REPEAT the self-test.
• Clear the DTCs. Repeat the HCM
• Is DTC U0155:87 still present? HCM . REFER to Headlamp Control Module (HCM)
in this section. TEST the system for normal operation.
No
Pinpoint Test AH: DTC U3003:16
Normal Operation
• DTC U3003:16 (Battery Voltage: Circuit Voltage Below Threshold) - sets continuous and on-demand
in the Headlamp Control Module (HCM) if the HCM detects battery voltage below 9 volts from the
HCM voltage supply circuit.

• HCM
PINPOINT TEST AH: DTC U3003:16
Section 414-01 .
PINPOINT TEST AH: DTC U3003:16 6090


AH1 RECHECK THE HCM DTCs &sp;
Yes
scan tool: HCM Self-Test. No
• Clear the DTCs. Repeat the HCM self-test. The system is operating correctly at this time. The
• Is DTC U3003:16 still present? DTC may have been set due to a previous low
battery voltage condition.
AH2 CHECK FOR CHARGING SYSTEM DTCs
IN THE PCM
Yes
• Enter the following diagnostic mode on the REFER to Section 414-00 .
scan tool: PCM Self-Test.
• Carry out the PCM Key ON Engine OFF No
(KOEO) self-test. GO to AH3 .
• Retrieve the continuous memory DTCs from
all modules.
• Is DTC P0620, P0622, P0625, P0626 or
P065B set in the PCM?
AH3 CHECK THE BATTERY CONDITION
AND STATE OF CHARGE
Yes
• Check the battery condition and verify that GO to AH4 .
the battery is fully charged. Refer to Section
414-01 . No
AH4 CHECK THE HCM VOLTAGE SUPPLY
Yes
• Ignition OFF. GO to AH5 .
• Disconnect: HCM C1600.
• Ignition ON. No
• Measure and record the voltage at the battery. REPAIR the circuit for high resistance. CLEAR
• Measure the voltage between the HCM the DTC. REPEAT the self-test.
C1600-10, circuit CBP42 (GN), harness side
and ground.

AH5 CHECK THE HCM GROUND CIRCUIT
PINPOINT TEST AH: DTC U3003:16 6091


• Disconnect: Negative Battery Cable. INSTALL a new HCM . REFER to Headlamp
• Measure the resistance between the HCM Control Module (HCM) in this section. TEST the
C1600-3, circuit GD121 (BK/YE), harness system for normal operation.
side and ground.
No
REPAIR the circuit for high resistance. CLEAR
Pinpoint Test AI: DTC U3003:17
Normal Operation
• DTC U3003:17 (Battery Voltage: Circuit Voltage Above Threshold) - sets continuous and on-demand
in the Headlamp Control Module (HCM) if the HCM detects battery voltage above 16 volts on the
voltage input circuit.

• HCM
PINPOINT TEST AI: DTC U3003:17
starting events.

AI1 CHECK FOR DTC B1317, B1676,
P0563 (PCM) OR U3003:17 SET IN
OTHER MODULES
Yes
• Enter the following diagnostic mode condition.
on the scan tool: Self-Test.
• Retrieve the continuous memory No
DTCs from all modules. GO to AI2 .
PINPOINT TEST AI: DTC U3003:17 6092

• Is DTC B1317, B1676, P0563

(PCM) or U3003:17 set in more
than one module?
AI2 CHECK THE BATTERY
VOLTAGE
Yes
• Turn off all interior/exterior lights REFER to Section 414-00 to diagnose an overcharging
and accessories. condition.
minutes while monitoring the battery GO to AI3 .
voltage.
• Does the battery voltage rise to 15.5
volts or higher?
AI3 RECHECK FOR DTC U3003:17
Yes
• Turn the engine off. INSTALL a new HCM . REFER to Headlamp Control
• Ignition ON. Module (HCM) in this section. TEST the system for
• Enter the following diagnostic mode normal operation.
on the scan tool: HCM Self-Test.
• Clear the DTCs and repeat the HCM No
on-demand self-test.. The system is operating normally at this time. The DTC
• Is DTC U3003:17 present? may have been set previously during battery charging or
PINPOINT TEST AI: DTC U3003:17 6093

Lighting Manual
Headlamp Adjustment
Special Tool(s)
Vision 100 Headlamp Aimer

Headlamp Aiming
1. The headlamp aiming procedure depends on what type of beam pattern the headlamp is equipped
with. Vehicles may come equipped with VOL, VOR or SAE only (includes sealed beam type)
headlamps. To identify the headlamp beam pattern, look on the headlamp lens. Molded in small
letters on the headlamp lens is one of the following:
• SAE
• VOL and SAE
• VOR and SAE
2. Once the headlamp beam pattern is identified, aim the headlamps using one of the following methods
as applicable.
• Photometric aimers can aim VOL-, VOR- and SAE-type headlamps only. This is the
preferred method of headlamp aiming.
• Visual or screen method aiming can be used to aim VOL-, VOR- and SAE-type headlamps
only.
• Mechanical aimers cannot be used with VOR- or VOL-type headlamps. Aerodynamic lamps
that can be aimed mechanically have 3 nibs molded into the lens of the lamp.
Photometric Aiming
1. For the photometric aiming procedure, refer to the appropriate photometric headlamp aimer
instruction manual.
Screen Method Aiming
All headlamp types
NOTE: Horizontal aim is not adjustable for VOL or VOR headlamps.
NOTE: Consult your state vehicle inspection manual for recommended tolerance ranges for visual aiming.
NOTE: The sight shield may need to be positioned or removed for access to the adjusters.
1. Before starting headlamp adjustment:

• check the tire inflation.
• check that no other load is in the vehicle other than a half tank of fuel.
Headlamp Adjustment 6094

• check that the headlamps are clean.
• check for correct headlamp operation.
• check that the vehicle is on level ground.
• if the vehicle is equipped with air suspension, make sure that the switch is on.
2. NOTE: The vertical wall or screen must be a minimum of 2.4 m (8 ft) wide.
Park the vehicle on a level surface approximately 7.6 m (25 ft) from the vertical wall or screen
directly in front of it.
3. NOTE: The center of the lamp is marked either on the lens (circle, crosshair or other mark) or on the
bulb shield internal to the lamp (crosshair or other mark).
Mark a horizontal reference line on the vertical wall or screen.
1. Measure the center of the headlamp height to ground and record the measurement.
2. Make a 2.4 m (8 ft) horizontal mark (using masking tape) on the vertical wall or screen at the
same distance from the ground as previously recorded.
4. NOTE: This procedure should be done in a dark environment to effectively see the headlamp beam
pattern.
Turn on the low beam headlamps to illuminate the wall or screen and open the hood.
5. NOTE: For SAE-type headlamps, the appearance of the beam pattern may vary between vehicles.
On the wall or screen, locate the high intensity area of the beam pattern. Place the top edge of the high
intensity zone even with the horizontal reference line.
SAE-type headlamps
6. In addition to the horizontal line marked in Step 3, a pair of vertical lines must be marked at the center
line of the headlamps on the wall or screen.
1. Mark the center line of the vehicle on the wall or screen.
2. Measure from the center of the headlamp to the center line of the vehicle.
3. Make two 1.5 m (5 ft) vertical marks (using masking tape) on the wall or screen at the same
distance from the vehicle center line as previously recorded.

7. On the wall or screen, locate the high intensity area of the beam pattern. Place the left edge of the high
intensity zone even with the vertical line corresponding to the headlamp being adjusted.
VOR-type headlamps
8. NOTE: The appearance of the VOR beam pattern may vary between vehicles.
Identify at the top edge of this high intensity area a distinct horizontal cutoff in the beam pattern. If
the top edge of this cutoff is not even with the horizontal reference line, the headlamp beam needs to
be adjusted.
VOL-type headlamps
9. For VOL-type headlamps, there is a distinct cutoff in the left portion of the beam pattern. The edge of
this cutoff should be positioned 50.2 mm (2 in) below the horizontal reference line.
1. Horizontal reference line.
2. Top edge of the beam pattern.
3. High intensity zone.
Mechanical Aiming
1. For the mechanical aiming procedure, refer to the appropriate mechanical headlamp aimer instruction
manual.


Lighting Manual
Front Fog Lamp Adjustment
Front Fog Lamp Adjustment Screw Location
1. NOTE: Horizontal aim is not required for this vehicle and is not adjustable. Consult your state
vehicle inspection center for recommended tolerance ranges for visual aiming.
Before starting the fog lamp assembly adjustment:
• make sure the vehicle is on level ground.

• check the tire inflation.
• make sure there are no other loads in the vehicle other than a half tank of fuel.
• make sure the fog lamps and headlamps are clean.
• make sure the headlamps are operating and are correctly aimed.
2. NOTE: The vertical wall screen must be a minimum of 2.4 m (8 ft) wide.
Park the vehicle on a level surface approximately 7.6 m (25 ft) from the vertical wall or screen
directly in front of it.
3. Measure the distance from the floor to the center of the fog lamp.
4. The correct visual aim for the fog lamps is with the top edge of the high-intensity zone 10 cm (4 in)
below the horizontal center of the fog lamps.
• Rotate the adjustment screw until the fog lamp beam is within specification.
Front Fog Lamp Adjustment 6098

Front Fog Lamp Adjustment Screw Location 6099

Lighting Manual
Autolamps Time Delay Adjustment
NOTE: The time delay can be programmed through the message center using the message center buttons (if
equipped) or using the following steps.
NOTE: Steps 2 through 5 must be carried out within a 10-second period.
1. Start with the ignition switch off and the headlamp switch in the AUTOLAMPS ON position.
2. Place the headlamp switch in the OFF position.
3. Place the ignition switch in the RUN position.
4. Place the ignition switch in the OFF position.
5. Place the headlamp switch in the AUTOLAMPS ON position. The exterior lamps turn on at this
point.
6. Wait the desired amount of time and place the headlamp switch in the OFF position (maximum of 3
minutes). The exterior lamps turn off and the autolamp time delay is now set.
Autolamps Time Delay Adjustment 6100

Lighting Manual
REMOVAL AND
INSTALLATION
Headlamp Assembly

1 - Headlamp assembly pin-type retainer (part of 13005)
2 W711676 Headlamp assembly bolts (4 required)
3 13008 Headlamp assembly
NOTE: Make sure the headlamp switch and the ignition switch are in the OFF position.
1. Remove the front bumper cover. For additional information, refer to Section 501-19 .
2. Remove the headlamp assembly pin-type retainer.
3. Remove the 4 bolts and the headlamp assembly.

Headlamp Assembly 6101

Headlamp Assembly 6102

Lighting Manual
REMOVAL AND
INSTALLATION
Headlamp Bulb - LH, Fusion
Low Beam
NOTE: Non-Hybrid shown, Hybrid similar.

1 13N019 Headlamp bulb protective cover
2 13N021 Headlamp low beam bulb
High Beam
Part
2 13N021 Headlamp high beam bulb
Headlamp Bulb - LH, Fusion 6103

3 - Headlamp high beam bulb electrical connector (part of

13008)
WARNING: The bulb contains gas under pressure. The bulb may shatter if the glass envelope is
scratched or if the bulb is dropped. Handle the bulb only by its base. Avoid touching the glass envelope.
Failure to follow these instructions may result in personal injury.
NOTE: The headlamp bulb should not be removed from the headlamp until just before a new bulb is
installed. Removing the bulb for an extended period of time may affect headlamp bulb performance.
Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the
headlamps with the bulb removed from the headlamp.
Low beam bulb
1. For vehicles equipped with a 3.0L engine, remove the air cleaner. For additional information, refer to
Section 303-12B .
High beam bulb
2. For Hybrid vehicles, remove the battery. For additional information, refer to Section 414-01 .
Low beam or high beam bulb
3. For non-Hybrid vehicles, if equipped remove the pin-type retainer and separate the small splash shield
from the core support.
4. For Hybrid vehicles, remove the air cleaner ACL outlet pipe. For additional information, refer to
Section 303-12D .
5. Remove the headlamp bulb protective cover.
6. Remove the headlamp bulb.


• Make sure the headlamp bulb protective cover is completely sealed.
High Beam 6104

High Beam 6105

Lighting Manual
REMOVAL AND
INSTALLATION
Headlamp Bulb - LH, MKZ
Low Beam
NOTE: High Intensity Discharge (HID) bulb shown, halogen bulb similar.
Part
3 - Headlamp low beam bulb electrical connector (part of
13008)
High Beam
Part
Headlamp Bulb - LH, MKZ 6106


13008)
High beam bulb
1. Remove the Air Cleaner ACL . For additional information, refer to Section 303-12C


High Beam 6107

Lighting Manual
REMOVAL AND
INSTALLATION
Headlamp Bulb - RH, Fusion
Low Beam

High Beam
Part
Headlamp Bulb - RH, Fusion 6108


13008)
Low beam bulb, all vehicles and High beam bulb, Hybrid vehicles
1. Position the engine coolant degas bottle aside.

1. If equipped detach the wiring harness retainer from the degas bottle.
2. Remove the bolt.
3. Remove the nut.
High beam bulb
2. For non Hybrid vehicles, remove the headlamp assembly. For additional information, refer to
Headlamp Assembly in this section.
3. For Hybrid vehicles, position aside the windshield washer reservoir filler tube.
High Beam 6109



High Beam 6110

Lighting Manual
REMOVAL AND
INSTALLATION
Headlamp Bulb - RH, MKZ
Low Beam
NOTE: High Intensity Discharge (HID) bulb shown, halogen bulb similar.
Part
3 - Headlamp low beam bulb electrical connector (part of
13008)
High Beam
Part
Headlamp Bulb - RH, MKZ 6111


13008)
Low beam bulb
1. Position the engine coolant degas bottle aside.

1. Detach the wiring harness retainer from the degas bottle.
2. Remove the bolt.
3. Remove the nut.
High beam bulb
2. Remove the headlamp assembly. For additional information, refer to Headlamp Assembly in this
section.


High Beam 6112

High Beam 6113

Lighting Manual
REMOVAL AND
INSTALLATION
Ballast

1 - Ballast screws (4 required) (part of 13008)
2 13C170 Ballast
3 - Ballast electrical connectors (part of 13008)
section.
2. Remove the 4 screws and the ballast.

Ballast 6114
Ballast 6115
Lighting Manual
REMOVAL AND
INSTALLATION
Fog Lamp
Fusion

1 W706805 Lower radiator air deflector outer screws (2 required)
2 W709976 Lower radiator air deflector front screws (4 required)
3 N807389 Lower radiator air deflector pin-type retainers (4
required)
5 17E811/17E810 Fog lamp bezel (LH/RH)
6 15K200 Fog lamp
7 - Fog lamp electrical connector (part of 14290)
MKZ
Fog Lamp 6116

1 17E811/17E810 Fog lamp bezel LH/RH

2 15K200 Fog lamp
All vehicles
100-02 .
Fusion
2. Remove the 2 outer screws and the 4 front screws from the lower radiator air deflector.
3. Remove the 4 pin-type retainers and the lower radiator air deflector.
All vehicles
4. NOTE: For MKZ, the fog lamp bezel tabs are located along the upper and lower edge close to each
corner. They are released from the front using a thin flat-bladed tool (such as a pocket screwdriver).
Usre not to damage the painted surface when releasing the tabs.
Release the 4 tabs and remove the fog lamp bezel.
5. Release the locking tabs and remove the fog lamp.

MKZ 6117
Lighting Manual
REMOVAL AND
INSTALLATION
Fog Lamp Bulb

1 W706805 Lower radiator air deflector outer screws (2 required)
2 W709976 Lower radiator air deflector front screws (4 required)
3 N807389 Lower radiator air deflector pin-type retainers (4
required)

6 13N021 Fog lamp bulb
Fog Lamp Bulb 6118

NOTE: The fog lamp bulb should not be removed from the fog lamp until just before a new bulb is installed.
Removing the bulb for an extended period of time may affect fog lamp bulb performance. Contaminants may
enter the fog lamp where they can settle on the lens and reflector. Never turn on the fog lamps with the bulb
removed.
100-02 .
2. Remove the 2 outer screws and the 4 front screws from the lower radiator air deflector.
3. Remove the 4 pin-type retainers and the lower radiator air deflector.
4. Disconnect the electrical connector and remove the fog lamp bulb.
• To install, reverse the removal procedure.
Fog Lamp Bulb 6119

Lighting Manual
REMOVAL AND
INSTALLATION
Parking Lamp Bulb - LH, Fusion
NOTE: Hybrid shown, non-Hybrid similar.
Part
1 - Front parking/turn lamp electrical connector (part of
14290)
2 13411 Front parking/turn lamp bulb socket
3 13466 Front parking/turn lamp bulb
NOTE: The front parking/turn lamp on non-Hybrid vehicles equipped with a 2.5L or 3.0L engine can be
accessed without removing any components.
1. For Hybrid vehicles, remove the battery tray. For additional information, refer to Section 414-01 .
2. For vehicles equipped with a 3.5L engine, remove the air cleaner. For additional information, refer to
Section 303-12C .
3. Disconnect the parking/turn lamp electrical connector.
4. Remove the front parking/turn lamp socket from the headlamp assembly.
• Remove the front parking/turn lamp bulb.
Parking Lamp Bulb - LH, Fusion 6120

Parking Lamp Bulb - LH, Fusion 6121

Lighting Manual
REMOVAL AND
INSTALLATION
Parking Lamp Bulb - LH, MKZ
NOTE: The air cleaner is shown removed for clarity.
Part
14290)
NOTE: The front parking/turn lamp can be accessed without removing any components.
1. Disconnect the electrical connector and remove the front parking lamp socket from the headlamp
assembly.
• Remove the front parking lamp bulb.
Parking Lamp Bulb - LH, MKZ 6122

Parking Lamp Bulb - LH, MKZ 6123

Lighting Manual
REMOVAL AND
INSTALLATION
Parking Lamp Bulb - RH, Fusion
NOTE: Hybrid shown, non-Hybrid similar.
Part
14290)
NOTE: The front parking/turn lamp on non-Hybrid vehicles can be accessed without removing any
components.
section.
2. Remove the front parking/turn lamp socket from the headlamp assembly.
• Remove the front parking/turn lamp bulb.
Parking Lamp Bulb - RH, Fusion 6124

Parking Lamp Bulb - RH, Fusion 6125

Lighting Manual
REMOVAL AND
INSTALLATION
Parking Lamp Bulb - RH, MKZ
Part
14290)
NOTE: The engine appearance cover can be removed for additional clearance.
1. Remove the bolt and the position aside the windshield washer reservoir filler tube.
2. Disconnect the electrical connector and remove the front parking lamp socket from the headlamp
assembly.
• Remove the front parking lamp bulb.
Parking Lamp Bulb - RH, MKZ 6126

Parking Lamp Bulb - RH, MKZ 6127

Lighting Manual
REMOVAL AND
INSTALLATION
Side Marker Lamp - Front
Fusion

1 - Side marker lamp electrical connector (part of 14290)
2 - Side marker lamp bulb socket (part of 13200)
3 W707501 Side marker lamp nut
4 13200 Side marker lamp
MKZ

1 - Side marker lamp electrical connector (part of 14290)
2 13411 Side marker lamp bulb socket
3 13466 Side marker lamp bulb
Side Marker Lamp - Front 6128

All vehicles
100-02 .
2. Remove the 4 pin-type retainers and position the fender splash shield aside.
3. Disconnect the side marker lamp electrical connector.
Fusion
4. Remove the nut and remove the side marker lamp.
MKZ
5. Remove the side marker lamp from the headlamp assembly.
All vehicles
MKZ 6129
Lighting Manual
REMOVAL AND
INSTALLATION
Headlamp Control Module (HCM)
Part
1 - Headlamp Control Module (HCM) electrical connector
(part of 14290)
2 W713134 HCM pin-type retainers (2 required)
3 13K198 HCM
1. If installing a new Headlamp Control Module (HCM), upload the module configuration information
to the scan tool. For additional information, refer to Section 418-01 .
2. Disconnect the HCM electrical connector.
3. Remove the 2 pin-type retainers and the HCM .

• If installing a new HCM , download the HCM configuration information from the sn tool into
the new HCM . For additional information, refer to Programmable Module Installation (PMI)
Section 418-01 .
Headlamp Control Module (HCM) 6130

Headlamp Control Module (HCM) 6131

Lighting Manual
REMOVAL AND
INSTALLATION
Light Sensor

1 13A018 Light sensor
2 - Light sensor electrical connector (part of 14401)
1. Using a suitable tool, remove the light sensor from the defroster grille.
Light Sensor 6132

Lighting Manual
REMOVAL AND
INSTALLATION
Stoplamp Switch

1 - Stoplamp switch electrical connector (part of 14290)
2 13480 Stoplamp switch
NOTICE: Do not press, pull or otherwise move the brake pedal while removing or installing the
stoplamp switch. The switch must be installed with the booster push rod attached to the brake pedal
and with the brake pedal in the at-rest position. Installing the switch with the brake pedal in any other
position results in incorrect adjustment and damage to the switch.
1. NOTICE: The switch plunger must be compressed for the switch to rotate in the bracket.
Attempting to remove the switch with the plunger extended (during brake pedal apply) results
in damage to the switch.
Rotate the stoplamp switch clockwise approximately one-eighth turn and remove the stoplamp switch.
Stoplamp Switch 6133

Stoplamp Switch 6134

Lighting Manual
REMOVAL AND
INSTALLATION
Headlamp Switch
Fusion

2 5404338 Headlamp switch bezel
3 - Headlamp switch electrical connectors (part of 14401)
4 11654 Headlamp switch
MKZ

2 - Headlamp switch bezel
3 - Headlamp switch electrical connector (part of 14401)
4 11654 Headlamp switch
Headlamp Switch 6135

2. NOTE: The headlamp switch bezel is removed by pushing from behind.
Release the tabs and remove the headlamp switch and bezel assembly.
3. NOTE: The 3 retaining tabs on the headlamp switch are located at approximately the 3, 6 and 11
o'clock positions when viewed from the front.
Release the tabs and separate the headlamp switch from the bezel.
MKZ 6136
Lighting Manual
REMOVAL AND
INSTALLATION
Hazard Flasher Lamp Switch

1 5413594 Instrument panel upper storage compartment
2 13A350 Hazard flasher lamp switch
1. Remove the instrument panel upper storage compartment. For additional information, refer to Section
501-12 .
2. Release the tabs and remove the hazard flasher lamp switch.
Hazard Flasher Lamp Switch 6137

Hazard Flasher Lamp Switch 6138

Lighting Manual
REMOVAL AND
INSTALLATION
Puddle Lamp

1 13B375 Puddle lamp
2 - Puddle lamp bulb socket (part of 17683)
1. Remove the exterior mirror glass. For additional information, refer to Section 501-09 .
2. Release the tab to remove the puddle lamp from the mirror housing.
3. NOTE: The LH puddle lamp bulb socket is rotated clockwise to remove and the RH puddle lamp
bulb socket is rotated counterclockwise to remove.
Rotate the puddle lamp bulb socket approximately one-quarter turn and remove it from the puddle
lamp.
4. NOTE: When rotating the bulb socket in the puddle lamp, the socket should come to a stop indicating
it is completely installed.
NOTE: An audible click can be heard when the puddle lamp is fully seated.
Puddle Lamp 6139

Puddle Lamp 6140

Lighting Manual
REMOVAL AND
INSTALLATION
Reversing Lamp Switch
Part
1 - Reversing lamp switch electrical connector (part of
7B229)
2 7B229 Reversing lamp switch
3 S995621 Reversing lamp switch gasket
100-02 .
2. Remove the fasteners and the lower engine splash shield.
3. NOTE: Discard the reversing lamp switch gasket.
Disconnect the electrical connector and remove the reversing lamp switch.

• Install a new reversing lamp switch gasket.
• Check the transmission fluid and fill as necessary. For additional information, refer to Section
308-03 .
Reversing Lamp Switch 6141

Reversing Lamp Switch 6142

Lighting Manual
REMOVAL AND
INSTALLATION
High Mounted Stoplamp
Parcel Shelf Mounted
Part
1 - High mounted stoplamp electrical connector (part of
14A005)
2 13A613 High mounted stoplamp
Luggage Compartment Lid Mounted

1 W709764 Luggage compartment lid moulding nuts (4 required)
2 W704141 High mounted stoplamp nuts (4 required)
3 13A417 High mounted stoplamp bracket
High Mounted Stoplamp 6143

Luggage Compartment Lid Mounted (Continued)

4 5442512 Luggage compartment lid moulding
5 - Electrical connectors (part of 13A412)
6 13A613 High mounted stoplamp
7 - High mounted stoplamp electrical connector
Removal and Installation /p>
Parcel shelf mounted
1. Disconnect the high mounted stoplamp electrical connector from within the luggage compartment.
2. Push the high mounted stoplamp rearward to disengage the forward tabs and remove the high
mounted stoplamp.
Luggage compartment lid mounted
3. Remove the luggage compartment lid trim panel.
4. Remove the 4 nuts and the luggage compartment lid moulding.

5. Remove the 4 nuts and the high mounted stoplamp bracket.
6. Release the 2 tabs and remove the high mounted stoplamp.

All vehicles
Luggage Compartment Lid Mounted (Continued) 6144

Luggage Compartment Lid Mounted (Continued) 6145

Lighting Manual
REMOVAL AND
INSTALLATION
Rear Lamp Assembly

1 W704141 Rear lamp assembly nuts (3 required)
2 13A505/13A504 Rear lamp assembly (LH/RH)
3 - Rear lamp assembly electrical connectors (part of
14A005)
1. Remove the pin-type retainer and position the luggage compartment trim panel aside.
2. Remove the 3 nuts and the rear lamp assembly.

• To install, tighten the nuts to 6 Nm (53 lb-in).
Rear Lamp Assembly 6146

Rear Lamp Assembly 6147

Lighting Manual
REMOVAL AND
INSTALLATION
Reversing Lamp

1 - Electrical connectors (part of 14A005)
2 - Reversing lamp outboard nuts (2 required)
3 W704141 Reversing lamp inboard nuts (5 required)
4 13405\13404 Reversing lamp (LH/RH)
1. Remove the pin-type retainers and the luggage compartment trim panel.
2. Disconnect the electrical connector(s).
3. Remove the 7 nuts and the reversing lamp.
Reversing Lamp 6148

Reversing Lamp 6149


Manual
Interior Lighting Control Module (ILCM) bolts 1.6 14
Reversing Lamp 6150


Manual
Interior Lighting
The SJB controls all of the interior lighting functions. The interior lighting system consists of the following
components:
• SJB
• Interior/map lamps
• Luggage compartment lamp
• Vanity mirror lamps
• Puddle lamps (if equipped)
• Scuff plate lamps (if equipped)
• Door ajar switches
• Luggage compartment lid ajar switch
• Ambient lighting module (Fusion) (if equipped)
• Ambient lighting switch (part of the traction control switch for Fusion) (if equipped)
• Ambient lighting select switch (MKZ (if equipped))
• Ambient lighting dimmer switch (MKZ (if equipped))
• Interior Lighting Control Module (ILCM) (MKZ)
The interior lighting system consists of up to 3 subsystems:
• Courtesy lamps
• Demand lamps
• Ambient lighting (if equipped)
Courtesy Lamps
The courtesy lamp subsystem consists of the interior dome lamps, the instrument panel dimmer switch, the
overhead console lamps, scuff plate lamps (if equipped) and the puddle lamps (if equipped). The SJB supplies
voltage to the courtesy lamps when the SJB receives the required input.
Demand Lamps
The demand lamps subsystem consists of the front map lamps, and the left and right vanity mirror lamps. The
demand lamps are provided voltage from the battery saver relay (integrated into the SJB ) when the battery
saver relay is energized.
Ambient Lighting - Fusion
The ambient lighting subsystem consists of the ambient lighting module, ambient lighting select switch, and
LEDs located throughout the vehicle. The LEDs are located on the center console cupholders, the storage bin,
and the front and rear footwells. The ambient lighting system is powered through the accessory delay relay.
The ambient lighting only illuminates when the key is in the on position.
Ambient Lighting - MKZ
Interior Lighting 6151

The ambient lighting feature provides illumination to the center console cup holders, the storage bin, door
map pockets and the front and rear footwells.
There are 4 different color LEDs (red, blue, green and white) housed within each LED assembly. By
illuminating various color combinations, the LEDs are able to produce 7 different colors of ambient light.
With each press of the ambient lighting select switch, the ILCM cycles through a different color variation.
With each press of the ambient lighting dimmer switch, the ILCM changes the brightness setting of the
ambient lighting or turns the ambient lighting feature off. The module retains the last color and brightness
setting between uses.
Interior Lighting Delay
The interior lighting delay feature provides temporary illumination of the courtesy lamps after the doors are
opened and then closed. The interior lighting delay feature keeps the courtesy lamps on for a period of 25
seconds after all the doors are closed. If during the 25-second delay time, the SJB detects that the ignition has
been turned out of off if the vehicle is locked using the Remote Keyless Entry (RKE) or the keypad, the
courtesy lamps are turned off.
Illuminated Entry
The illuminated entry requests the courtesy lamps to illuminate when the ignition is OFF and either the RKE
transmitter UNLOCK button is pressed, or the vehicle is unlocked using the keypad. The illuminated entry
requests the courtesy lamps off:
• after 25 seconds have elapsed.

• when the ignition is switched to the OFF position.
• when the RKE transmitter LOCK button is pressed.
• when the vehicle is locked using the keypad
Illuminated Exit
NOTE: The puddle lamps are not illuminated for the illuminated exit feature.
The illuminated exit requests the courtesy lamps to illuminate for 25 second when all doors are closed and the
ignition key is removed from the ignition lock cylinder. The illuminated exit deactivates:
• when the ignition key is inserted into the ignition lock cylinder.
• when a door becomes ajar.
• after 25 seconds have elapsed.
Theater Lighting
The theater lighting feature ramps-up the courtesy lamps intensity over 0.7 second when courtesy lamp
activation is requested. The theater lighting feature ramps-down the courtesy lamps intensity over 1.7 seconds
when interior lighting deactivation is requested by any feature other than the panic alarm or battery saver.
Battery Saver
The SJB provides automatic shut-off of the demand lamps and courtesy lamps after a 10-minute time-out
period in order to save battery voltage. A timer in the SJB is started when the ignition is turned to the OFF
position and all the doors and liftgate are closed. When 10 minutes have elapsed, voltage is automatically shut
off to the lamps by the SJB .



Manual
Interior Lighting
Special Tool(s)


Flex Probe Kit
When a vehicle door is ajar with the vehicle speed less than 15 km/h (9 mph) or 5 km/h (3 mph) for puddle
lamps, or a request from the instrument panel dimmer switch is received, the SJB provides voltage to the
interior courtesy and puddle lamp circuits. The SJB controls all interior lighting functions and timing by
monitoring inputs from the door ajar switches, the instrument panel dimmer switch, the Remote Keyless Entry
(RKE) transmitter and vehicle speed.
Interior Lamp Arbitrator
The SJB chooses between the interior lighting, dome defeat, interior lighting delay, illuminated entry,
illuminated exit and battery saver to determine which feature has precedence of activating and deactivating
the interior lamps.
Ambient Lighting - Fusion
The ambient lighting feature provides illumination to the center console cup holders, the storage bin, and the
front and rear footwells The ambient lighting feature is powered by the accessory delay relay, which allows
the ambient lighting feature to be used independent of the parking lamps status.
The ambient lighting module provides voltage and ground to the LEDs. There are 3 different color (red, blue
and green) LEDs housed within each LED assembly. By illuminating various color combinations, the LEDs
are able to produce 7 different colors of ambient light. The ambient lighting switch is an input to the ambient
lighting module. With each press of the ambient lighting switch, the ambient lighting module cycles through a
different color variation or turns the ambient lighting feature off. The module retains the last color setting
between uses.
Ambient Lighting - MKZ

The Interior Lighting Control Module (ILCM) provides voltage to the LEDs. There are 4 different color LEDs
(red, blue, green and white) housed within each LED assembly. By illuminating various color combinations,
the LEDs are able to produce 7 different colors of ambient light. The ambient lighting select switch and
ambient lighting dimmer switch are inputs to the ILCM . With each press of the ambient lighting select
switch, the ILCM cycles through a different color variation. With each press of the ambient lighting dimmer
switch, the ILCM changes the brightness setting of the ambient lighting or turns the ambient lightieature off.
The module retains the last color and brightness setting between uses.
Battery Saver
The SJB provides automatic shut-off of the demand lamps and courtesy lamps after a 10-minute time-out
period in order to save battery voltage. A timer in the SJB is started when the ignition is turned to the OFF
position and all the doors are closed. When the 10-minute time-out period has elapsed, the voltage is
automatically shut off to the lamps by the SJB .
To activate the battery saver feature, one of the following events must occur:
• The ignition is turned to any position other than OFF.

• Any door becomes ajar.
• The UNLOCK button of the RKE transmitter is pressed.
• A key is inserted into the ignition lock cylinder.
• A valid keypad code is entered.
• The luggage compartment lid is opened.
• The instrument panel dimmer switch is placed in the DOME LAMP position.
• The headlamp switch is placed in the PARKING LAMPS or HEADLAMPS ON position.
• The multifunction switch is placed in the FLASH-TO-PASS position.
• The key is inserted into the ignition lock cylinder.

The SJB FET protected output circuits for the interior lighting system are the interior courtesy lamp and
puddle lamp output circuits.
The Interior Lighting Control Module (ILCM) operates in a similar manner. The ILCM FET protected output
circuits for the ambient lighting system are the ambient lighting output circuits.
Electrical

fuse(s):
♦ 9 (15A)
♦ 10 (15A)
♦ 25 (10A)
connectors
• Bulb(s)
• Courtesy lamps
• Map lamps
• Puddle lamp(s)
• Scuff plate lamp(s) (if
equipped)
• Vanity lamps
• Instrument panel dimmer
switch
• Glove compartment lamp
• Ambient lighting switch (if
equipped)




• If the scan tool responds with no communication with the SJB , refer to Section 418-00 .
DTC Charts

B106E Solid State Driver The module has temporarily disabled an output because an excessive
Disabled Due to current draw exists (such as a short to ground). The Smart Junction Box
Short Circuit (SJB) cannot enable the output until the cause of the short is corrected.
ADDRESS all other DTCs first. After the cause of the concern is corrected,
B106F Module Disabled The module has permanently disabled an output because an excessive
Due to External current draw fault (such as a short to ground) has exceeded the limits that
Fault the SJB can withstand. The cause of the excessive current draw MUST be
corrected before a new SJB is installed. ADDRESS all other DTCs first.
After the cause of the concern is corrected, INSTALL a new SJB . REFER to
Section 419-10 . TEST the system for normal operation.
B1320 Driver Door Ajar GO to Pinpoint Test F .
Circuit Open
B1328 GO to Pinpoint Test F .

Passenger Door
Ajar Circuit Open
B1331 Decklid Ajar GO to Pinpoint Test E .
Rear Door Circuit
Failure
B1336 Door Ajar RR GO to Pinpoint Test F .
Circuit Open
B1572 Door Ajar LR GO to Pinpoint Test F .
Circuit Open
B213A Digital Dimmer REFER to Section 413-00 .
Switch Input
Circuit Failure
B2A35 Interior Lighting If the interior courtesy lamps are inoperative, GO to Pinpoint Test C .
Output Circuit
Open If the interior courtesy lamps stay on continuously, GO to Pinpoint Test F .
B2A36 Interior Lighting GO to Pinpoint Test C .
Output Circuit
Short to Ground
B2A38 Floor Lamp DIAGNOSE all other DTCs and symptoms first. If no other DTCs or symptoms
Circuit Short to are present, INSPECT the SJB and C2280a for bent pins, loose or corroded
Ground connections.
If no concerns are found, INSTALL a new SJB . REFER to Section 419-10 .

B2A39 Puddle Lamp If the puddle lamps are inoperative, GO to Pinpoint Test D .
Output Circuit
Open If the puddle lamps are always on, GO to Pinpoint Test G .
B2A3A Puddle Lamp GO to Pinpoint Test D .
Output Circuit
Short to Ground
All other - REFER to the Diagnostic Trouble Code (DTC) Chart in Section 419-10 .
DTCs
Interiorighting Control Module (ILCM) DTC Chart

B106E Solid State Driver The module has temporarily disabled an output because an excessive
Disabled Due to current draw exists (such as a short to ground). The Interior Lighting
Short Circuit Control Module (ILCM) cannot enable the output until the cause of the
short is corrected. ADDRESS all other DTCs first. After the cause of the
concern is corrected, CLEAR the DTCs. REPEAT the self-test.
B106F Module Disabled Due The module has permanently disabled an output because an excessive
to External Fault current draw fault (such as a short to ground) has exceeded the limits
that the SJB can withstand. The cause of the excessive current draw
MUST be corrected before a new ILCM is installed. ADDRESS all other
DTCs first. After the cause of the concern is corrected, INSTALL a new
ILCM . REFER to Interior Lighting Control Module (ILCM) in this section.


B1342 ECU Is Faulted INSTALL a new ILCM . REFER to Interior Lighting Control Module
(ILCM) in this section. TEST the system for normal operation.
B2477 Module REFER to Section 418-01 .
Configuration Failure
B2A21 One Or More REFER to Section 418-01 .
Configuration Files
Missing Or Corrupt
B2B00 Ambient Light Zone GO to Pinpoint Test N .
1 Red Circuit Open
1 Red Circuit Short to
Ground
1 Green Circuit Open
1 Green Circuit Short
to Ground
1 Blue Circuit Open
1 Blue Circuit Short
to Ground
1 Signature Circuit
Open
1 Signature Circuit
Short to Ground
B2B18 Ambient Light If the ambient lighting is inoperative or does not cycle through the color
Switch Input Fault combinations, GO to Pinpoint Test M .
If the ambient lighting does not cycle through the brightness settings, GO to
Pinpoint Test O .
U0140 Lost Communication GO to Pinpoint Test P .
With Body Control
Module (GEM)
U2050 No Application CARRY OUT Programmable Module Installation (PMI). REFER to Section
Present 418-01 .
All - REFER to the Diagnostic Trouble Code (DTC) Chart in Section 419-10 .
other
DTCs
Symptom Chart
Symptom Chart
Pinpoint Tests

Pinpoint Test A: The Courtesy Lamps Do Not Illuminate With A Door Open
Refer to Wiring Diagrams Cell 110 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Power Door Locks for
Refer to Wiring Diagrams Cell 113 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Luggage Compartment
Lid Release for schematic and connector information.
Normal Operation
When any door is open, the ajar switch opens the circuit to the Smart Junction Box (SJB). The SJB monitors
the ajar circuits, and based on the ajar status, the SJB supplies voltage to the courtesy lamps.
When any door is opened, a correct unlock code from the keyless entry keypad or an unlock request from a
programmed Remote Keyless Entry (RKE) transmitter is detected, the SJB provides voltage to the courtesy
lamps.

• Door ajar switch
• SJB
PINPOINT TEST A: THE COURTESY LAMPS DO NOT ILLUMINATE WITH A DOOR OPEN

A1 CHECK THE COURTESY LAMP OPERATION
USING THE INSTRUMENT PANEL DIMMER
SWITCH
Yes
• Operate the courtesy lamps using the instrument GO to A2 .
panel dimmer switch.
• Do the interior courtesy lamps illuminate using No
the instrument panel dimmer switch? GO to Pinpoint Test C .
A2 CHECK THE DOOR AJAR SWITCH
OPERATION
Yes
• Ignition OFF. INSTALL a new door latch in question.
• Disconnect: Suspect Door Ajar Switch. REFER to Section 501-14 . TEST the
• Do the interior lamps illuminate? system for normal operation.
No
GO to A3 .
A3 CHECK THE AJAR SWITCH CIRCUIT FOR A
SHORT TO GROUND

• Disconnect: SJB C2280c. Yes

• Measure the resistance between the suspect ajar GO to A4 .
switch, harness side and ground as follows:
No
REPAIR the circuit in question for a short
to ground. TEST the system for normal
operation.
Location Connector-Pin Circuit
LH front door C525-8 CPL26 (GN/VT)
RH front door C603-8 CPL31 (WH)
LH rear door C704-8 CPL36 (GN)
RH rear door C804-8 CPL39 (YE)

Yes
♦ damaged pins
present.
Pinpoint Test B: The Courtesy Lamps Do Not Illuminate From The Instrument Panel Dimmer Switch
Refer to Wiring Diagrams Cell 89 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Interior Lamps for
Normal Operation
The Smart Junction Box (SJB) turns the courtesy lamps on and off by monitoring the dimmer switch input
and the dome lamp request input circuits. When the instrument panel dimmer switch is pushed to the second
detent up, the backlighting dim up circuit and the dome request circuit are both requested to indicate a request
to turn the courtesy lamps on. When the instrument panel dimmer switch is pushed to the second detent down,
the backlighting dim down circuit and the dome request circuit are both requested to indicate a request to turn
the courtesy lamps off.
PINPOINT TEST A: THE COURTESY LAMPS DO NOT ILLUMINATE WITH A DOOR OPEN 6161
• SJB
PINPOINT TEST B: THE COURTESY LAMPS DO NOT ILLUMINATE FROM THE INSTRUMENT PANEL DIMMER
SWITCH

B1 CHECK THE DIMMABLE BACKLIGHTING
ILLUMINATION
Yes
• Turn the headlamps switch to the PARKING LAMPS ON
position. No
• Monitor the instrument panel dimmable backlighting while REFER to Section 413-00 to
pushing the instrument panel dimmer switch from full on to full continue diagnosis of the
off. dimmable backlighting
• Does the instrument cluster illumination intensity change illumination.
with the instrument panel dimmer switch position?
B2 CHECK THE INSTRUMENT PANEL DIMMER SWITCH
Yes
• Turn the headlamps switch to the OFF position. INSTALL a new instrument
• Disconnect: Instrument Panel Dimmer Switch C2065. panel dimmer switch. REFER
• Measure the voltage between the instrument panel dimmer to Section 413-00 . TEST the
switch C2065-2, circuit CLN28 (GN/BU), harness side and system for normal operation.
ground.
No
GO to B3 .

B3 CHECK THE DOME LAMP REQUEST INPUT CIRCUIT
FOR AN OPEN
Yes
• Disconnect: SJB C2280b. GO to B4 .
• Measure the resistance between the SJB C2280b-51, circuit
CLN28 (GN/BU), harness side and the instrument panel No
dimmer switch C2065-2, circuit CLN28 (GN/BU), harness side. REPAIR the circuit. TEST the
• Is the resistance less than 5 ohms? system for normal operation.
Yes


♦ damaged pins
connector.
Pinpoint Test C: The Interior Courtesy Lamp(s) Are Inoperative
Normal Operation
Power is supplied to the interior courtesy lamps and cargo lamp by the Smart Junction Box (SJB) fuse 9
(15A). Based on the input status, the SJB supplies voltage to the interior courtesy lamps.

A continuous DTC that sets when the SJB has temporarily shut down the output driver.
• B106E - The module has temporarily disabled the interior courtesy lamp output because
Solid State an excessive current draw exists (such as a short to ground). The SJB cannot
Driver enable the interior courtesy lamp output until the cause of the short is corrected,
Disabled the DTCs have been cleared and a successful self-test is run.
Due to Short
Circuit
• B106F - driver. The module has permanently disabled the interior courtesy lamp output
Module because an excessive current draw fault (such as a short to ground) has exceeded
Disabled the limits that the SJB can withstand. The cause of the excessive current draw
Due to MUST be corrected before a new SJB is installed.
External
Fault
An on-demand DTC that sets when the SJB detects an open from the courtesy lighting
• B2A35 - output circuit.
Interior
Lighting
Output
Circuit Open
• B2A36 - from the courtesy lighting output circuit.
Interior
Lighting
Output
Circuit Short
To Ground
PINPOINT TEST B: THE COURTESY LAMPS DO NOT ILLUMINATE FROM THE INSTRUMENT
6163
PANEL D
• Fuse
• Interior lamp
• SJB
PINPOINT TEST C: THE INTERIOR COURTESY LAMP(S) ARE INOPERATIVE
Result / Action to
Test Step
Take
C1 CHECK THE OPERATION OF ALL THE INTERIOR COURTESY
LAMPS
Yes
• Ignition OFF. VERIFY the SJB
• Push up the instrument panel dimmer switch to the second up detent and fuse 9 (15A) is
observe the interior courtesy lamps. OK. If OK, GO to
• Are the interior courtesy lamps inoperative? C4 .
If not OK, REFER

to the Wiring
Diagrams Manual
to identify the
possible causes of
the circuit short.
After the repair:
If no DTCs are
present, TEST the
system for normal
operation.
If DTC B106E is
present, CLEAR
the DTCs and
REPEAT the
self-test (required
to enable the
interior courtesy
lamp output
driver if DTC
B106E is present)
. TEST the system
for normal
operation.
If DTC B106F is
present, INSTALL
a new SJB .

REFER to Section
419-10 . TEST the
system for normal
operation.
No
GO to C2 .
C2 CHECK FOR VOLTAGE TO THE INTERIOR LAMP
Yes
• Push the instrument panel dimmer switch down out of the DOME LAMP GO to C3 .
position.
• Disconnect: Inoperative Lamp. No
• Push up the instrument panel dimmer switch to the second up detent. REPAIR circuit
• Measure the voltage between the inoperative lamp, harness side and ground VLN33 (GY/VT)
as follows: for an open. TEST
the system for
normal operation.

Front C930-3 VLN33 (GY/VT)
Front (MKZ with ambient lighting) C9035-3 VLN33 (GY/VT)
Rear C901-1 VLN33 (GY/VT)
LH scuff plate C3251-1 VLN33 (GY/VT)
RH scuff plate C3250-1 VLN33 (GY/VT)

C3 CHECK FOR VOLTAGE TO THE INTERIOR LAMP USING THE
CONNECTOR GROUND
PINPOINT TEST C: THE INTERIOR COURTESY LAMP(S) ARE INOPERATIVE 6165

• Measure the voltage between the inoperative interior lamp connector, Yes
harness side as follows: INSTALL a new
interior lamp for
the lamp in
question. REFER
to Interior Lamp -
Connector-Pin/ Connector-Pin/ Front or Interior
Inoperative Lamp Circuit Circuit Lamp - Rear in this
Front C930-3 C930-1 section. TEST the
system for normal
VLN33 (GY/VT) GD139 (BK/YE) operation.
Front (MKZ with ambient C9035-3 C9035-1 No
lighting) REPAIR the
VLN33 (GY/VT) GD139 (BK/YE) ground circuit in
Rear C901-1 C901-2 question for an
open. TEST the
VLN33 (GY/VT) GD139 (BK/YE) system for normal
LH scuff plate C3251-1 C3251-3 operation.
VLN33 (GY/VT) GD126 (BK/WH)

RH scuff plate C3250-1 C3250-3
VLN33 (GY/VT) GD126 (BK/WH)

C4 BYPASS THE SJB
Yes
• Ignition OFF. REMOVE the
• Disconnect: SJB C2280a. jumper wire. GO to
• NOTE: If the jumper wire fails, refer to the Wiring Diagrams Manual to C5 .
identify the possible causes of the circuit short. After the repair: If no DTCs
are present, test the system for normal operation. If DTC B106E is present, No
clear the DTCs and repeat the self-test (required to enable the courtesy REMOVE the
lamp output driver if DTC B is present). Test the system for normal jumper wire.
operation. If DTC B106F is present, install a new SJB . Refer to Section REPAIR circuit
419-10 . Test the system for normal operation. VLN33 (GY/VT)
for an open.
PINPOINT TEST C: THE INTERIOR COURTESY LAMP(S) ARE INOPERATIVE 6166

• Connect a fused jumper wire between the SJB C2280a-9, circuit VLN33 CLEAR the DTCs.
(GY/VT), harness side and battery positive. REPEAT the
self-test.
• Do the courtesy lamps illuminate?

Yes
• Disconnect all the SJB connectors. INSTALL a new
• Check for: SJB . REFER to
♦ corrosion Section 419-10 .
♦ damaged pins TEST the system
♦ pushed-out pins for normal
• Connect all the SJB connectors and make sure they seat correctly. operation.
The system is
operating correctly
at this time. The
concern may have
been caused by a
loose or corroded
connector.
Pinpoint Test D: The Puddle Lamp(s) Are Inoperative
Normal Operation
Power is supplied to the puddle lamps through the Smart Junction Box (SJB) fuse 10 (15A). Based on the
input status, the SJB supplies voltage to the puddle lamps. The puddle lamps have separate ground circuits.

• B106E - driver. The module has temporarily disabled the puddle lamp output because an
Solid State excessive current draw exists (such as a short to ground). The SJB cannot enable
Driver the puddle lamp output until the cause of the short is corrected, the DTCs have
Disabled Due been cleared an a successful self-test is run.
to Short
Circuit

• B106F - A continuous DTC that sets when the SJB has permanently shut down the output
Module driver. The module has permanently disabled the puddle lamp output because an
Disabled Due excessive current draw fault (such as a short to ground) has exceeded the limits
to External that the SJB can withstand. The cause of the excessive current draw MUST be
Fault corrected before a new SJB is installed.
An on-demand DTC that sets when the SJB detects an open on the puddle lamp output
• B2A39 - circuit.
Puddle Lamp
Output
Circuit Open
A continuous and on-demand DTC that sets when the SJB detects a short to ground on
• B2A3A - the puddle lamp output circuit. This DTC may also set as a result when the SJB fuse
Puddle Lamp 10 (15A) has failed or is removed.
Output
Circuit Short
To Ground
• Fuse
• Exterior mirror
PINPOINT TEST D: THE PUDDLE LAMP(S) ARE INOPERATIVE

D1 CHECK THE PUDDLE LAMP OPERATION
Yes
• Ignition OFF. VERIFY the SJB fuse 10
• Operate the instrument panel dimmer switch to the DOME LAMP (15A) is OK. If OK, GO to
position. D2 .
• Are both the puddle lamps inoperative?
If not OK, REFER to the
Wiring Diagrams Manual to
identify the possible causes
After the repair: if no DTCs

are present, TEST the

CLEAR the DTCs and
(required to enable the
puddle lamp output driver
if DTC B106E is present) .
operation.
PINPOINT TEST D: THE PUDDLE LAMP(S) ARE INOPERATIVE 6168


INSTALL a new SJB .
operation.
No
GO to D3 .
D2 BYPASS THE SJB
Yes
• Operate the instrument panel dimmer switch out of the DOME REMOVE the jumper wire.
LAMP position. GO to D3 .
• Disconnect: SJB C2280c.
• NOTE: If the jumper wire fails, refer to the Wiring Diagrams No
Manual to identify the possible causes of the circuit short. After REMOVE the jumper wire.
the repair: If no DTCs are present, test the system for normal REPAIR circuit CLN25
operation. If DTC B106E is present, clear the DTCs and repeat the (VT) for an open. CLEAR
self-test (required to enable the courtesy lamp output driver if the DTCs. REPEAT the
DTC B106E is present). Test the system for normal operation. If self-test.
DTC B106F is present, install a new SJB . Refer to Section 419-10
. Test the system for normal operation.
• Connect a fused jumper wire between the SJB C2280c-12, circuit
CLN25 (VT), harness side and battery positive.
• Do the puddle lamps illuminate?

D3 CHECK FOR VOLTAGE TO THE EXTERIOR MIRROR
Yes
• Operate the instrument panel dimmer switch out of the DOME GO to D4 .
LAMP position.
• Disconnect: Suspect Exterior Mirror. No
• Operate the instrument panel dimmer switch to the DOME LAMP REPAIR circuit CLN25
position. (VT) for an open. TEST the
• For Fusion, measure the voltage between the LH exterior mirror system for normal operation.
C517-4, circuit CLN25 (VT), harness side and ground; or between
the RH exterior mirror C625-4, circuit CLN25 (VT), harness side
and ground.

• For MKZ, measure the voltage between the LH exterior mirror

C522-5, circuit CLN25 (VT), harness side and ground; or between
the RH exterior mirror C626-5, circuit CLN25 (VT), harness side
and ground.

D4 CHECK FOR VOLTAGE TO THE EXTERIOR MIRROR
Yes
• For Fusion, measure the voltage between the LH exterior mirror INSTALL a new exterior
C517-4, circuit CLN25 (VT), harness side and the LH exterior mirror in question. REFER
mirror C517-6, circuit GD126 (BK/WH), harness side; or between to Section 501-09 . TEST
the RH exterior mirror C625-4, circuit CLN25 (VT), harness side the system for normal
and the RH exterior mirror C625-6, circuit GD139 (BK/YE), operation.
harness side.
No
REPAIR the ground circuit
in question for an open.
operation.
• For MKZ, measure the voltage between the LH exterior mirror

C522-5, circuit CLN25 (VT), harness side and LH exterior mirror
C522-7, circuit GD126 (BK/WH), harness side; or between the RH
exterior mirror C626-5, circuit CLN25 (VT), harness side and the
RH exterior mirror C626-7, circuit GD139 (BK/YE), harness side.

Pinpoint Test E: The Luggage Compartment Lamp Is Inoperative/Always On
Normal Operation
Power is supplied to the luggage compartment lamp from the demand lighting circuit. Ground for the luggage
compartment lamp is controlled by the luggage compartment latch. When the luggage compartment lid is
opened, a switch inside the latch closes and completes the path to ground.
• DTC B1331 (Decklid Ajar Rear Door Circuit Failure) - an on-demand DTC that sets when the SJB
detects an open from the luggage compartment lid ajar input circuit.

• Luggage compartment lid latch
PINPOINT TEST E: THE LUGGAGE COMPARTMENT LAMP IS INOPERATIVE/ALWAYS ON

E1 DETERMINE IF THE LAMP IS INOPERATIVE OR
ALWAYS ON
Yes
• Open the luggage compartment lid and observe the GO to E2 .
luggage compartment lamp.
• Is the luggage compartment lamp illuminated? No
GO to E3 .
E2 CHECK THE LUGGAGE COMPARTMENT LAMP
GROUND CONTROLLED CIRCUIT FOR A SHORT TO
GROUND
Yes
• Disconnect: Luggage Compartment Lid Latch C429. REPAIR circuit CLN13 (WH/BU)
• Does the luggage compartment lamp continue to for a short to ground. TEST the
illuminate? system for normal operation.
No
INSTALL a new luggage
compartment lid latch. REFER to
Section 501-14 . TEST the system
E3 CHECK FOR VOLTAGE TO THE LUGGAGE
COMPARTMENT LAMP

• Disconnect: Luggage Compartment Lamp C4198. Yes

• Measure the voltage between the luggage compartment
lamp C4198-1, circuit CLN09 (YE/GN), harness side and No
ground. REPAIR circuit CLN09 (YE/GN) for
an open. TEST the system for
normal operation.

COMPARTMENT LAMP USING THE CONNECTOR
GROUND
Yes
• Measure the voltage between the luggage compartment INSTALL a new luggage
lamp C4198-1, circuit CLN09 (YE/GN), harness side and compartment lamp. TEST the system
the luggage compartment lamp C4198-2, circuit CLN13 for normal operation.
(WH/BU), harness side.
No
GO to E5 .

COMPARTMENT LID LATCH
Yes
• Connect: Luggage Compartment Lamp C4198. INSTALL a new luggage
• Disconnect: Luggage Compartment Lid Latch C429. compartment lid latch. REFER to
• Measure the voltage between the luggage compartment lid Section 501-14 . TEST the system
latch C429-2, circuit CLN13 (WH/BU), harness side and for normal operation.
ground.
No
REPAIR circuit CLN13 (WH/BU)
for an open. TEST the system for
normal operation.
PINPOINT TEST E: THE LUGGAGE COMPARTMENT LAMP IS INOPERATIVE/ALWAYS ON 6172

Pinpoint Test F: The Interior Courtesy Lamps Stay On Continuously
Refer to Wiring Diagrams Cell 110 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Power Door Locks for
Refer to Wiring Diagrams Cell 113 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Luggage Compartment
Lid Release for schematic and connector information.
Normal Operation
When any door or liftgate is opened, a correct unlock code from the keyless entry keypad or an unlock request
from a programmed Remote Keyless Entry (RKE) transmitter is detected, the Smart Junction Box (SJB)
supplies voltage to the interior courtesy lamps.

An on-demand DTC that sets when the SJB detects an open from the LH
• B1320 - Driver Door Ajar front door ajar input circuit.
Circuit Open
An on-demand DTC that sets when the SJB detects an open from the RH
• B1328 - Passenger Door front door ajar input circuit.
Ajar Circuit Open
An on-demand DTC that sets when the SJB detects an open from the RH
• B1336 - Door Ajar RR rear door ajar input circuit.
Circuit Open
An on-demand DTC that sets when the SJB detects an open from the LH
• B1572 - Door Ajar LR rear door ajar input circuit.
Circuit Open
An on-demand DTC that sets when the SJB detects a short to voltage
• B2A35 - Interior Lighting from the courtesy lamp output circuit.
Output Circuit Open

• Door ajar switch
• SJB
PINPOINT TEST F: THE INTERIOR COURTESY LAMPS STAY ON CONTINUOUSLY
NOTICE: Use the correct probe a) when making measurements. Failure to use the correct probe
adapter(s) may damage the connector.

F1 CHECK THE SJB DTCs

NOTE: Make sure all doors are closed before running the Yes
SJB on-demand self-test. GO to F2 .
• Carry out the SJB on-demand self-test. No

• Is DTC B1320, B1328, B1336 or B1572 recorded? GO to F5 .
F2 CHECK FOR VOLTAGE TO THE DOOR AJAR
SWITCH
Yes
• Disconnect: Suspect Door Ajar Switch.
• Measure the voltage between the suspect door ajar switch, No
harness side and ground as follows: GO to F4 .
Suspect Door Ajar

Switch Connector-Pin Circuit
LH front C525-8 CPL26
(GN/VT)
RH front C603-8 CPL31 (WH)
LH rear C704-8 CPL36 (GN)
RH rear C804-8 CPL39 (YE)

F3 CHECK FOR VOLTAGE TO THE DOOR AJAR
SWITCH USING THE CONNECTOR GROUND
Yes
• Measure the voltage between the suspect door ajar switch, INSTALL a new door latch for the
harness side and ground as follows: ajar switch in question. REFER to
Section 501-14 . CLEAR the DTCs.
No
Suspect Door Ajar REPAIR the ground circuit in
Switch Connector-Pin Circuit question for an open. CLEAR the
LH front C525-8 C525-6 DTCs. REPEAT the self-test.
CPL26 (GN/VT) GD126

(BK/WH)
RH front C603-8 C603-6
CPL31 (WH) GD139
PINPOINT TEST F: THE INTERIOR COURTESY LAMPS STAY ON CONTINUOUSLY 6174

(BK/YE)
LH rear C704-8 C704-6
CPL36 (GN) GD126

(BK/WH)
RH rear C804-8 C804-6
CPL39 (YE) GD139

(BK/YE)

F4 CHECK THE DOOR AJAR SWITCH INPUT CIRCUIT
FOR AN OPEN
Yes
• Disconnect: SJB C2280c. GO to F5 .
• Measure the resistance between the suspect door ajar
switch, harness side and the SJB , harness side as follows: No
self-test.
Suspect Door Ajar SJB

Switch Connector-Pin Connector-Pin Circuit
LH front C525-8 C2280c-14 CPL26
(GN/VT)
RH front C603-8 C2280c-2 CPL31
(WH)
LH rear C704-8 C2280c-3 CPL36
(GN)
RH rear C804-8 C2280c-15 CPL39 (YE)

F5 CHECK THE SJB INTERIOR COURTESY LAMP
OUTPUT CIRCUIT FOR A SHORT TO VOLTAGE
PINPOINT TEST F: THE INTERIOR COURTESY LAMPS STAY ON CONTINUOUSLY 6175

NOTE: Make sure the doors are closed for correct test Yes
results. REPAIR circuit VLN33 (GY/VT)
for a short to voltage. CLEAR the
• Ignition OFF. DTCs. REPEAT the self-test.
• Ignition ON. No
• Observe the interior courtesy lamps. GO to F6 .
• Do the interior courtesy lamps continue to illuminate?
Yes
♦ damaged pins
Pinpoint Test G: The Puddle Lamps Stay On Continuously
Normal Operation
When the request from the instrument panel dimmer switch is detected, any door is opened, a correct unlock
code from the keyless entry keypad or an unlock request from a programmed Remote Keyless Entry (RKE)
transmitter is detected, the Smart Junction Box (SJB) supplies voltage to the puddle lamps.
• DTC B2A39 (Puddle Lamp Output Circuit Open) - an on-demand DTC that sets when the SJB detects
a short to voltage from the puddle lamp output circuit.

• SJB
PINPOINT TEST G: THE PUDDLE LAMPS STAY ON CONTINUOUSLY
NOTICE: Use the correct probe adapt(s) when making measurements. Failure to use the correct probe
adapter(s) may damage the connector.

G1 CHECK THE INTERIOR COURTESY
LAMPS
Yes
• Ignition OFF. GO to Pinpoint Test F .
• Are the interior courtesy lamps illuminated?

No
GO to G2 .
G2 CHECK THE SJB PUDDLE LAMP OUTPUT
Yes
• Disconnect: SJB C2280c. REPAIR circuit CLN25 (VT) for a short to
• Ignition ON. voltage. CLEAR the DTCs. REPEAT the
• Do the puddle lamps continue to illuminate? self-test.
No
GO to G3 .
G3 CHECK FOR CORRECT SJB OPERATION
Yes
• Check for: 419-10 . TEST the system for normal operation.
♦ corrosion
♦ damaged pins No
• Connect all the SJB connectors and make sure The concern may have been caused by a loose
they seat correctly. or corroded connector.
still present.
Pinpoint Test H: All The Demand Lamps Are Inoperative
Normal Operation
The Smart Junction Box (SJB) supplies voltage to the demand lamps. The demand lamps are ground through
one circuit. The glove compartment lamp (MKZ only) is case grounded.

• SJB
PINPOINT TEST H: ALL THE DEMAND LAMPS ARE INOPERATIVE

H1 CHECK THE OPERATION OF THE INTERIOR
COURTESY LAMPS
Yes
PINPOINT TEST G: THE PUDDLE LAMPS STAY ON CONTINUOUSLY 6177

• Operate the courtesy lamps by opening the LH front No

door. GO to Pinpoint Test A .
• Do the courtesy lamps illuminate?
H2 CHECK CIRCUIT CLN09 (YE/GN) FOR AN OPEN
Yes
• Disconnect: SJB C2280d. REMOVE the jumper wire. GO to H3 .
• Connect a fused jumper wire between the SJB
C2280d-21, circuit CLN09 (YE/GN), harness side and No
battery positive. REMOVE the jumper wire. REPAIR
the circuit. TEST the system for normal
operation.
• Do the demand lamps illuminate?

H3 CHECK FOR CORRECT SJB OPERATION
Yes
♦ damaged pins
present. connector.
Pinpoint Test I: An Individual Demand Lamp Is Inoperative
Normal Operation
The Smart Junction Box (SJB) supplies voltage to the demand lamps. The demand lamps are grounded
through one circuit. The glove compartment lamp (MKZ only) is case grounded.

• Demand lamp
PINPOINT TEST H: ALL THE DEMAND LAMPS ARE INOPERATIVE 6178

PINPOINT TEST I: AN INDIVIDUAL DEMAND LAMP IS INOPERATIVE

I1 CHECK FOR VOLTAGE TO THE DEMAND LAMP
Yes
• Disconnect: Suspect Demand Lamp.
• Ignition ON. No
• Measure the voltage between the suspect demand lamp, REPAIR the circuit in question.
harness side and ground as follows: TEST the system for normal
operation.
Location Connector-Pin Circuit

RH vanity mirror lamp C906-1 CLN09
(YE/GN)
LH vanity mirror lamp C907-1 CLN09
(YE/GN)
Front C930-2 CLN09
(YE/GN)
Front (MKZ only) C9035-2 CLN09
(YE/GN)
Rear (with moonroof) C921-3 CLN09
(YE/GN)
Rear (without C901-3 CLN09
moonroof) (YE/GN)
Glove compartment C254-1 CLN09
lamp (YE/GN)

I2 CHECK FOR VOLTAGE TO THE DEMAND LAMP
PINPOINT TEST I: AN INDIVIDUAL DEMAND LAMP IS INOPERATIVE 6179

• Measure the voltage between the inoperative demand Yes

lamp, harness side and ground as follows: INSTALL a new demand lamp for
the suspect lamp. TEST the system
No
Inoperative Connector-Pin/ Connector-Pin/ REPAIR the circuit in question.
Lamp Circuit Circuit TEST the system for normal
LH vanity C907-1 C907-2 operation.
mirror lamp
CLN09 (YE/GN) GD139 (BK/YE)
RH vanity C906-1 C906-2
mirror lamp
Front C930-2 C930-1

Front (MKZ C9035-2 C9035-6
only)
Rear (with C921-3 C921-2
moonroof)
Rear (without C901-3 C901-2
moonroof)
Pinpoint Test J: The Battery Saver Does Not Deactivate After Time-Out
PINPOINT TEST I: AN INDIVIDUAL DEMAND LAMP IS INOPERATIVE 6180

Normal Operation
The Smart Junction Box (SJB) controls the battery saver function. The battery saver function provides
automatic shutoff of the interior lamps (courtesy lamps and demand lamps) after 10 minutes have elapsed in
order to save battery power.

• SJB
PINPOINT TEST J: THE BATTERY SAVER DOES NOT DEACTIVATE AFTER TIME-OUT

J1 CHECK THE SJB IGNITION SWITCH PIDs
Yes
• Monitor the SJB ignition switch PIDs REFER to Section 211-05 .
(IGN_A_ECU, IGN_O_ECU, IGN_R_ECU and
IGN_S_ECU) while rotating the ignition switch
through all positions.
• Do the ignition switch PIDs agree with the
ignition switch positions?
J2 CHECK THE DEMAND LAMP VOLTAGE
SUPPLY CIRCUIT FOR A SHORT TO VOLTAGE
Yes
• Ignition OFF. REPAIR the circuit. TEST the system for
• Disconnect: SJB C2280e. normal operation.
• Ignition ON.
• Operate the demand lamps. No
• Do the demand lamps illuminate? GO to J3 .
J3 CHECK FOR CORRECT SJB OPERATION
Yes
♦ damaged pins
• Operate the system and verify the concern is still a loose or corroded connector.
present.
Pinpoint Test K: The Ambient Lighting Is Inoperative - Fusion

Normal Operation
When the ignition key is in the RUN or ACC position, the ambient lighting module supplies voltage and
ground to the LEDs located in the floor console cup holders, storage tray, storage bin, door map pockets and
the front and rear footwells. The ambient lighting switch is used to cycle through the 8 color combinations or
to turn the ambient lighting feature off. There are 4 different color (red, blue, green and white) LEDs housed
within each LED assembly.
When the ignition key is in the RUN or ACC position, the ambient lighting switch and the ambient lighting
module receive voltage. When the ambient lighting switch (a momentary contact switch) is pressed, voltage is
routed to the ambient lighting module indicating a request for the module to cycle the ambient lighting to the
next setting.
• Fuse
• Ambient lighting harness
• Ambient lighting switch
• Ambient lighting module
PINPOINT TEST K: THE AMBIENT LIGHTING IS INOPERATIVE - FUSION
Result / Action
Test Step
to Take
K1 CHECK FOR VOLTAGE TO THE
AMBIENT LIGHTING MODULE
Yes
• Disconnect: Ambient Lighting Module
C3256. No
• Ignition ON. VERIFY the
• Measure the voltage between the ambient Smart Junction
lighting module C3256-1, circuit CBX07 Box (SJB) fuse
(GN/RD), harness side and ground. 41 (15A) is OK.
If OK, REPAIR
the circuit
CBX07
(GN/RD) for an
open. TEST the
system for
normal
operation. If not
OK, REFER to
the Wiring
Diagrams
PINPOINT TEST J: THE BATTERY SAVER DOES NOT DEACTIVATE AFTER TIME-OUT 6182
Manual to
identify the
possible causes
of the circuit
short.
K2 CHECK THE INPUT FROM THE
AMBIENT LIGHTING SWITCH
Yes
• While pressing and releasing the ambient GO to K6 .
lighting switch, measure the voltage
between the ambient lighting module No
C3256-2, circuit CLN54 (BN/YE), If voltage is
harness side and ground. always present,
GO to K3 .
If no voltage is
present, GO to
K4 .
• Is the voltage greater than 10 volts

with the switch pressed and 0 volts
with the switch released?
K3 CHECK THE AMBIENT LIGHTING
SWITCH INPUT CIRCUIT FOR A SHORT
TO VOLTAGE
Yes
• Ignition OFF. REPAIR the
• Disconnect: Traction Control/Ambient circuit for a
Lighting Switch C2304. short to voltage.
• Ignition ON. TEST the
• Measure the voltage between the ambient system for
lighting module C3256-2, circuit CLN54 normal
(BN/YE), harness side and ground. operation.
No
INSTALL a
new traction
control/ambient
lighting switch.
REFER to
Section 206-09 .
TEST the
system for
normal
operation.
AMBIENT LIGHTING SWITCH
PINPOINT TEST K: THE AMBIENT LIGHTING IS INOPERATIVE - FUSION 6183


• Connect: Ambient Lighting Module GO to K5 .
C3256.
• Disconnect: Traction Control/Ambient No
Lighting Switch C2304. VERIFY the
• Ignition ON. SJB fuse 41
• Measure the voltage between the ambient (15A) is OK. If
lighting switch C2304-5, circuit CBP41 OK, REPAIR
(BU), harness side and ground. the circuit for an
open. TEST the
system for
normal
operation. If not
OK, REFER to
the Wiring
Diagrams
Manual to
identify the
possible causes
of the circuit
short.
K5 BYPASS THE AMBIENT LIGHTING
SWITCH
Yes
• Connect and remove a fused jumper wire INSTALL a
between the ambient lighting switch new traction
C2304-5, circuit CBP41 (BU), harness control/ambient
side and the ambient lighting switch lighting switch.
C2304-4, circuit CLN54 (BN/YE), REFER to
harness side. Section 206-09 .
TEST the
system for
normal
operation.
No
REPAIR the
circuit for an
open. TEST the
system for
• Do the ambient LEDs illuminate and
normal
cycle through a color change each time
operation.
the jumper wire is connected and
removed?
AMBIENT LIGHTING MODULE USING
Yes
• Measure the voltage between the ambient GO to K7 .
lighting module C3256-1, circuit CBX07
(GN/RD), harness side and the ambient No
lighting module C3256-8, circuit GD908 REPAIR the
(BK), harness side. circuit for an
open. TEST the

system for
normal
operation.

K7 CHECK THE AMBIENT LIGHTING
HARNESS
Yes
• Check any of the diode circuits between
the ambient lighting module, harness side No
as follows: REPAIR or
INSTALL a
new ambient
lighting harness.
TEST the
system for
Connector-Pin/Circuit Connector-Pin/Circuit
C3256-5 C3256-4 normal
operation.
CLN45 (GN) RLN44 (BN)
C3256-6 C3256-4
CLN46 (BU) RLN44 (BN)

C3256-7 C3256-4
CLN44 (OG) RLN44 (BN)
• Does the meter indicate the circuit is

good?
K8 CHECK FOR CORRECT AMBIENT
LIGHTING MODULE OPERATION
Yes
• Disconnect the ambient lighting module INSTALL a
connector. new ambient
• Check for: lighting module.
♦ corrosion REFER to
♦ damaged pins Ambient
♦ pushed-out pins Lighting
Module in this

• Connect the ambient lighting module section. TEST

connector and make sure it seats the system for
correctly. normal
• Operate the system and verify the operation.
The system is
operating
correctly at this
time. The
concern may
have been
caused by a
loose or
corroded
connector.
Pinpoint Test L: The Ambient Lighting Does Not Cycle Through All Color Combinations - Fusion
Normal Operation
When the ignition key is in the RUN or ACC position, the ambient lighting module supplies voltage and
ground to the LEDs located in the floor console cup holders, storage tray, storage bin, door map pockets and
the front and rear footwells. The ambient lighting switch is used to cycle through the 8 color combinations or
to turn the ambient lighting feature off. There are 4 different color (red, blue, green and white) LEDs housed
within each LED assembly.
When the ignition key is in the RUN or ACC position, the ambient lighting switch and the ambient lighting
module receive voltage. When the ambient lighting switch (a momentary contact switch) is pressed, voltage is
routed to the ambie lighting module indicating a request for the module to cycle the ambient lighting to the
next setting.

• Ambient lighting switch
• Ambient lighting module
PINPOINT TEST L: THE AMBIENT LIGHTING DOES NOT CYCLE THROUGH ALL COLOR COMBINATIONS -
FUSION

L1 CHECK THE INPUT FROM THE AMBIENT
LIGHTING SWITCH


• Disconnect: Ambient Lighting Module C3256. GO to L .
• Ignition ON.
• While pressing and releasing the ambient lighting No
switch, measure the voltage between the ambient If voltage is always present, GO to L2 .
lighting module C3256-2, circuit CLN54 (BN/YE),
harness side and ground. If no voltage is present, GO to L3 .
• Is the voltage greater than 10 volts with the switch

pressed, and 0 volts with the switch released?
L2 CHECK THE AMBIENT LIGHTING SWITCH INPUT
Yes
• Ignition OFF. REPAIR the circuit for a short to
• Disconnect: Traction Control/Ambient Lighting Switch voltage. TEST the system for normal
C2304. operation.
• Ignition ON.
• Measure the voltage between the ambient lighting No
module C3256-2, circuit CLN54 (BN/YE), harness side INSTALL a new traction
and ground. control/ambient lighting switch.
REFER to Section 206-09 . TEST the

L3 CHECK FOR VOLTAGE TO THE AMBIENT
LIGHTING SWITCH
Yes
• Disconnect: Traction Control/Ambient Lighting Switch
C2304. No
• Connect: Ambient Lighting Module C3256. VERIFY the Smart Junction Box
• Ignition ON. (SJB) fuse 41 (15A) is OK. If OK,
• Measure the voltage between the ambient lighting switch REPAIR the circuit for an open. TEST
C2304-5, circuit CBP41 (BU), harness side and ground. the system for normal operation. If not
PINPOINT TEST L: THE AMBIENT LIGHTING DOES NOT CYCLE THROUGH ALL COLOR COMBINATIO
6187

L4 BYPASS THE AMBIENT LIGHTING SWITCH
Yes
• Connect and remove a fused jumper wire between the INSTALL a new traction
ambient lighting switch C2304-5, circuit CBP41 (BU), control/ambient lighting switch.
harness side and the ambient lighting switch C2304-4, REFER to Section 206-09 . TEST the
circuit CLN54 (BN/YE), harness side. system for normal operation.
No
REPAIR the circuit for an open. TEST
• Do the ambient LEDs illuminate and cycle through a

color change each time the jumper wire is connected
and removed?
L5 CHECK THE AMBIENT LIGHTING HARNESS
Yes
• Check any of the diode circuits between the ambient
lighting module, harness side as follows: No
REPAIR or INSTALL a new ambient
lighting harness. TEST the system for
normal operation.
C3256-5 C3256-4

C3256-6 C3256-4

C3256-7 C3256-4
PINPOINT TEST L: THE AMBIENT LIGHTING DOES NOT CYCLE THROUGH ALL COLOR COMBINATIO
6188
• Does the meter indicate the circuit is good?

L6 CHECK FOR CORRECT AMBIENT LIGHTING
MODULE OPERATION
Yes
• Disconnect the ambient lighting module connector. INSTALL a new ambient lighting
• Check for: module. REFER to Ambient Lighting
♦ corrosion Module in this section. TEST the
♦ damaged pins system for normal operation.
♦ pushed-out pins
• Connect the ambient lighting module connector and No
make sure it seats correctly. The system is operating correctly at
• Operate the system and verify the concern is still this time. The concern may have been
Pinpoint Test M: The Ambient Lighting Is Inoperative - MKZ
Normal Operation
The Interior Lighting Control Module (ILCM) supplies voltage and ground to the LEDs located in the floor
console cup holders, storage tray, storage bin, door map pockets and the front and rear footwells. The ambient
lighting select switch is used to cycle through the 7 color combinations or to turn the ambient lighting feature
off. There are 4 different color (red, blue, green and white) LEDs housed within each LED assembly.
The ILCM sends a voltage signal to the ambient lighting select switch. When the ambient lighting switch (a
momentary contact switch) is pressed, the voltage signal is routed toround indicating a request for the module
to cycle the ambient lighting to the next color setting.
• DTC B2B18 (Ambient Light Switch Input Fault) - a continuous and on-demand DTC that sets when
the ILCM detects a short to ground from the ambient lighting select switch input circuit.

• Ambient lighting select switch
• ILCM

PINPOINT TEST M: THE AMBIENT LIGHTING IS INOPERATIVE - MKZ

M1 CHECK FOR COMMUNICATION TO THE ILCM
Yes
• Enter the following diagnostic mode on the scan tool: ILCM GO to M2 .
DataLogger.
• Carry out the network test using the scan tool. No
• Does the scan tool communicate with the ILCM ? REFER to Section 418-00 .
M2 CHECK THE INPUT FROM THE AMBIENT LIGHTING
SWITCH
Yes
• Enter the following diagnostic mode on the scan tool: ILCM GO to M8 .
DataLogger.
• While pressing and releasing the ambient lighting switch, No
monitor the ILCM ambient lighting select switch PID If the PID always reads active,
(AmbiColor). GO to M3 .
• Does the PID read active with the switch pressed and idle
with the switch released? If the PID always reads idle, GO
to M4 .
M3 CHECK THE AMBIENT LIGHTING SWITCH FOR A
SHORT TO GROUND
Yes
• Disconnect: Ambient Lighting Switch C2306. GO to M4 .
• Enter the following diagnostic mode on the scan tool: ILCM
DataLogger. No
• Monitor the ILCM ambient lighting select switch PID INSTALL a new ambient
(AmbiColor). lighting select switch. REFER to
• Does the PID still read active? Ambient Lighting Switch in this
normal operation.
M4 CHECK THE AMBIENT LIGHTING SELECT SWITCH
Yes
• Disconnect: ILCM C2301.
• Measure the resistance between the ILCM C2301-8, circuit No
CPL60 (WH/BN), harness side and ground. REPAIR circuit CPL60
(WH/BN) for a short to ground.
self-test.

M5 BYPASS THE AMBIENT LIGHTING SELECT SWITCH
PINPOINT TEST M: THE AMBIENT LIGHTING IS INOPERATIVE - MKZ 6190


• Disconnect: Ambient Lighting Select Switch C2306. GO to M6 .
• Ignition ON.
• Enter the following diagnostic mode on the scan tool: ILCM No
DataLogger. GO to M7 .
• Monitor the ILCM ambient lighting select switch PID
(AmbiColor).
• Connect a fused jumper wire between the ambient lighting
select switch C2306-2, circuit CPL60 (WH/BN), harness side
and ground.
• Does the PID read active?

M6 BYPASS THE AMBIENT LIGHTING SELECT SWITCH
Yes
• Enter the following diagnostic mode on the scan tool: ILCM REMOVE the jumper wire.
DataLogger. INSTALL a new ambient
• Monitor the ILCM ambient lighting select switch PID lighting switch. REFER to
(AmbiColor). Ambient Lighting Switch in this
• Connect and remove a fused jumper wire between the ambient section. TEST the system for
lighting switch C2306-2, circuit CLN60 (BN/YE), harness side normal operation.
and the ambient lighting switch C2306-6, circuit GD908 (BK),
harness side. No
REMOVE the jumper wire.
REPAIR circuit GD908 (BK)
for an open. TEST the system
• Does the PID read active?

M7 CHECK THE AMBIENT LIGHTING SELECT SWITCH
Yes
CLN60 (BN/YE), harness side and the ambient lighting select REPAIR circuit CLN60
switch C2306-2, circuit CLN60 (BN/YE), harness side. (BN/YE) for an open. TEST the
• Is the resistance less than 5 ohms? system for normal operation.
M8 CHECK THE AMBIENT LIGHTING RETURN CIRCUIT


• Check the diode circuits between the ILCM , harness side as GO to M9 .
follows:
No
REPAIR circuit RLN44 (BU)
for an open. TEST the system
C2301-4 C2301-20

C2301-3 C2301-20

C2301-6 C2301-20

C2301-5 C2301-20
CLN57 (WH) RLN44 (BN)

M9 CHECK FOR CORRECT ILCM OPERATION
Yes
• Disconnect the ILCM connector. INSTALL a new ILCM .
• Check for: REFER to Interior Lighting
♦ corrosion Control Module (ILCM) in this
• Connect the ILCM connector and make sure it seats correctly.
connector.
Pinpoint Test N: The Ambient Lighting Does Not Cycle Through All Color Combinations - MKZ

Normal Operation
The Interior Lighting Control Module (ILCM) supplies voltagend ground to the LEDs located in the floor
console cup holders, storage tray, storage bin, door map pockets and the front and rear footwells. The ambient
lighting select switch is used to cycle through the 7 color combinations or to turn the ambient lighting feature
off. There are 4 different color (red, blue, green and white) LEDs housed within each LED assembly.
The ILCM sends a voltage signal to the ambient lighting select switch. When the ambient lighting switch (a
momentary contact switch) is pressed, the voltage signal is routed to ground indicating a request for the
module to cycle the ambient lighting to the next color setting.

A continuous and on-demand DTC that sets when the ILCM detects
• B2B00 - Ambient Light Zone an open from the ambient lighting zone 1 red circuit.
1 Red Circuit Open
A continuous and on-demand DTC that sets when the ILCM detects a
• B2B01 - Ambient Light Zone short to ground from the ambient lighting zone 1 red circuit.
1 Red Circuit Short to
Ground
inuous and on-demand DTC that sets when the ILCM detects an open
• B2B02 - Ambient Light Zone from the ambient lighting zone 1 green circuit.
1 Green Circuit Open
• B2B03 - Ambient Light Zone short to ground from the ambient lighting zone 1 green circuit.
1 Green Circuit Short to
Ground
• B2B04 - Ambient Light Zone an open from the ambient lighting zone 1 blue circuit.
1 Blue Circuit Open
• B2B05 - Ambient Light Zone short to ground from the ambient lighting zone 1 blue circuit.
1 Blue Circuit Short to
Ground
• B2B06 - Ambient Light Zone an open from the ambient lighting zone ure circuit.
1 Signature Circuit Open
• B2B07 - Ambient Light Zone short to ground from the ambient lighting zone 1 signature circuit.
1 Signature Circuit Short to
Ground

• Ambient lighting select switch
• ILCM

PINPOINT TEST N: THE AMBIENT LIGHTING DOES NOT CYCLE THROUGH ALL COLOR COMBINATIONS - MKZ

N1 CHECK THE INPUT FROM THE AMBIENT
LIGHTING SWITCH
Yes
• Enter the following diagnostic mode on the scan tool: GO to N2 .
ILCM DataLogger.
• While pressing and releasing the ambient lighting switch, No
monitor the ILCM ambient lighting select switch PID GO to Pinpoint Test M .
(AmbiColor).
• Does the PID read active with thetch pressed and idle
with the switch released?
N2 CHECK THE AMBIENT LIGHTING HARNESS
Yes
• Check the diode circuits between the ILCM , harness side
as follows: No
REPAIR the circuit in question or
INSTALL a new ambient lighting
harness. TEST the system for normal
operation.
C2301-4 C2301-20

C2301-3 C2301-20

C2301-6 C2301-20

C2301-5 C2301-20
CLN57 (WH) RLN44 (BN)

N3 CHECK FOR CORRECT ILCM OPERATION
PINPOINT TEST N: THE AMBIENT LIGHTING DOES NOT CYCLE THROUGH ALL COLOR COMBINATIO
6194
• Disconnect the ILCM connector. Yes

• Check for: INSTALL a new ILCM . REFER to
♦ corrosion Interior Lighting Control Module
♦ damaged pins (ILCM) in this section. TEST the
♦ pushed-out pins system for normal operation.
• Connect the ILCM connector and make sure it seats
correctly. No
• Is the concern still present? this time. The concern may have been
caused by a loose or corroded
connector.
Pinpoint Test O: The Ambient Lighting Does Not Cycle Through Brightness Settings - MKZ
Normal Operation
The Interior Lighting Control Module (ILCM) sends 2 voltage reference signals to the ambient lighting
dimmer switch (dim up or didown). When the ambient lighting dimmer switch (a momentary contact switch)
is pressed (dim up or dim down), the voltage signal is routed to the ground indicating a request for the module
to cycle the ambient lighting to the next dim up or dim down setting.
• DTC B2B18 (Ambient Light Switch Input Fault) - a continuous and on-demand DTC that sets when
the ILCM detects a short to ground from the ambient lighting dim up or dim down input circuit.

• Ambient lighting dimmer switch
• ILCM
PINPOINT TEST O: THE AMBIENT LIGHTING DOES NOT CYCLE THROUGH BRIGHTNESS SETTINGS - MKZ

O1 CHECK THE INPUT FROM THE AMBIENT LIGHTING
SWITCH
Yes
• Enter the following diagnostic mode on the scan tool: ILCM
DataLogger. No
• While pressing and releasing the ambient lighting dimmer If the PID indicates up or down
switch up and down, monitor the ILCM ambient lighting with the switch not pressed, GO
dimmer switch PID (AmbiDim). to O2 .
• Does the PID agree with the switch positions?
If the PID indicates idle when

the switch is pressed up or down,

GO to O4 .
O2 CHECK THE AMBIENT LIGHTING DIMMER SWITCH
Yes
• Disconnect: Ambient Lighting Dimmer Switch C2305.
• Ignition ON. No
• Enter the following diagnostic mode on the scan tool: ILCM INSTALL a new ambient
DataLogger. lighting dimmer switch. REFER
• Monitor the ILCM ambient lighting dimmer switch PID to Ambient Lighting Switch in
(AmbiDim). this section. TEST the system for
• Does the PID still indicate up or down? normal operation.
INPUT CIRCUITS FOR A SHORT TO GROUND
Yes
CLN61 (WH/VT), harness side and ground; and between the REPAIR the circuit in question
ILCM C2301-19, circuit CLN62 (BN/BU), harness side and for a short to ground. CLEAR
ground. the DTCs. REPEAT the self-test.

DIMMER SWITCH DIM DOWN CIRCUIT
Yes
• Disconnect: Ambient Lighting Dimmer Switch C2305.
• Ignition ON. No
• Enter the following diagnostic mode on the scan tool: ILCM GO to O5 .
DataLogger.
• Monitor the ILCM ambient lighting dimmer switch PID
(AmbiDim).
• Connect and remove a fused jumper wire between the ambient
lighting switch C2305-3, circuit CLN61 (WH/VT), harness
side and ground.
PINPOINT TEST O: THE AMBIENT LIGHTING DOES NOT CYCLE THROUGH BRIGHTNESS6196
SETTINGS
• Does the PID indicate down?

DIM DOWN CIRCUIT FOR AN OPEN
Yes
CLN61 (WH/VT), harness side and the ambient lighting REPAIR circuit CLN62
dimmer switch C2305-3, circuit CLN61 (WH/VT), harness (BN/BU) for an open. TEST the
side. system for normal operation.

DIMMER SWITCH DIM UP CIRCUIT
Yes
• Enter the following diagnostic mode on the scan tool: ILCM REMOVE the jumper wire. GO
DataLogger. to O8 .
• Monitor the ILCM ambient lighting dimmer switch PID
(AmbiDim). No
• Connect a fused jumper wire between the ambient lighting REMOVE the jumper wire. GO
dimmer switch C2305-7, circuit CLN62 (BN/BU), harness to O7 .
side and ground.
• Does the PID indicate up?

DIM UP CIRCUIT FOR AN OPEN
SETTINGS

• Disconnect: ILCM C2301. GO to O9 .
• Measure the resistance between the ILCM C2301-9, circuit
CLN62 (BN/BU), harness side and the ambient lighting No
dimmer switch C2305-7, circuit CLN62 (BN/BU), harness REPAIR circuit CLN61
side. (WH/VT) for an open. TEST the

O8 BYPASS THE AMBIENT LIGHTING DIMMER SWITCH
Yes
• Enter the following diagnostic mode on the scan tool: ILCM INSTALL a new ambient
DataLogger. lighting dimmer. REFER to
• Monitor the ILCM ambient lighting dimmer switch PID Ambient Lighting Switch in this
(AmbiDim). section. TEST the system for
• Connect a fused jumper wire between the ambient lighting normal operation.
dimmer switch C2305-3, circuit CLN61 (WH/VT), harness
side and the ambient lighting switch C2305-4, circuit GD908 No
(BK), harness side. GO to O9 .
• Does the PID indicate down?

O9 CHECK FOR CORRECT ILCM OPERATION
Yes
• Disconnect the ILCM connector. INSTALL a new ILCM .
• Check for: REFER to Interior Lighting
♦ corrosion Control Module (ILCM) in this
• Connect the ILCM connector and make sure it seats correctly.
• Is the concern still present? The system is operating correctly
at this time. The concern may
corroded connector.
Pinpoint Test P: DTC U0140 - Lost Communication With Smart Junction Box (SJB)
SETTINGS
Normal Operation
• DTC U0140 (Lost Communication With SJB ) - set by the Interior Lighting Control Module (ILCM)
if data messages received from the SJB over the Medium Speed Controller Area Network (MS-CAN)
are missing. For a complete list of all network messages, refer to Section 418-00 .

• ILCM
PINPOINT TEST P: DTC U0140 - LOST COMMUNICATION WITH SJB

P1 VERIFY CUSTOMER CONCERN
Yes
symptom present. No
• Is an observable symptom present? The system is operating correctly at this time. The DTC
P2 CHECK THE COMMUNICATION
NETWORK
Yes
• Enter the following diagnostic mode on GO to P3 .
• Does the SJB pass the network test? REFER to Section 418-00 .
P3 RECHECK THE ILCM DTCs
Yes
• Clear the DTCs. Repeat the ILCM GO to P4 .
self-test.
• Is DTC U0140 still present? No
The system is operating correctly at this time. The DTC
P4 CHECK FOR DTC U0140 or U0140:00
SET IN OTHER MODULES
Yes
• Clear all DTCs. INSTALL a new SJB . REFER to Section 419-10 .
• Ignition OFF. CLEAR the DTCs. REPEAT the self-test.
• Ignition ON.
• Enter the following diagnostic mode on INSTALL a new ILCM . REFER to Interior Lighting
the scan tool: Self-Test. Control Module (ILCM) in this section. TEST the
• Retrieve the continuous memory DTCs system for normal operation.
from all modules.
• Is DTC U0140 set in the Driver Seat
Module (DSM) or the Driver Door
Module (DDM)?
PINPOINT TEST P: DTC U0140 - LOST COMMUNICATION WITH SJB 6199

PINPOINT TEST P: DTC U0140 - LOST COMMUNICATION WITH SJB 6200


Manual
REMOVAL AND
INSTALLATION
Interior Lamp - Front

1 54519A70 Overhead console
2 - Overhead console screws (2 required)
3 - Overhead console storage door (part of 54519A70)
4 - Overhead console retainer brackets
1. Open the overhead console storage door to access the screws.

• Remove the 2 screws.
2. Pull the overhead console down and remove the console from the headliner retainer.
Interior Lamp - Front 6201

Interior Lamp - Front 6202


Manual
REMOVAL AND
INSTALLATION
Interior Lamp - Rear

1 13783 Rear interior lamp lens
2 13776 Rear interior lamp
3 - Rear interior lamp electrical connector (part of 14334)
1. Remove the rear interior lamp lens.
2. Release the 2 retaining clips (through the access holes) and remove the rear interior lamp assembly.
Interior Lamp - Rear 6203

&nbsp
Interior Lamp - Rear 6204


Manual
REMOVAL AND
INSTALLATION
Interior Lighting Control Module (ILCM)
Part
1 - Interior Lighting Control Module (ILCM) bolts (2
required)
2 13E702 ILCM
3 - ILCM electrical connector (part of 13E720)
1. Remove the passenger air bag module. For additional information, refer to Section 501-20B .
2. Remove the 2 bolts and the Interior Lighting Control Module (ILCM).
• To install, tighten to 1.6 Nm (14 lb-in).
Interior Lighting Control Module (ILCM) 6205

Interior Lighting Control Module (ILCM) 6206


Manual
REMOVAL AND
INSTALLATION
Ambient Lighting Module
Part
2 045A76 Floor console finish panel
3 - Ambient lighting module electrical connector (part of
14D375)
4 W701679 Ambient lighting module screws (2 required)
5 13C788 Ambient lighting module
1. If equipped with an automatic transaxle, remove the selector lever trim ring.
2. If equipped with a manual transaxle, remove the gearshift knob.
3. Open the storage compartment door.
4. Pull the floor console finish panel straight up to release the retainer clips and remove the finish panel.
• Disconnect the ambient lighting module electrical connector.
5. Remove the 2 screws and the ambient lighting module.
Ambient Lighting Module 6207

Ambient Lighting Module 6208


Manual
REMOVAL AND
INSTALLATION
Ambient Lighting Switch
NOTE: Ambient select switch shown, ambient dimmer switch similar.

3 13D806 Ambient lighting select switch
2. NOTE: The switch bezel is removed by pushing from behind.
Remove the switch bezel.
3. Release the tabs and remove the ambient lighting switch.
Ambient Lighting Switch 6209

Ambient Lighting Switch 6210

SECTION 418-00: Module Communications 2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid
Network Workshop Manual
Communications Network
Multiplexing is a method of sending 2 or more signals simultaneously over a single circuit. Multiplexing is
used to allow 2 or more electronic modules (nodes) to communicate simultaneously over a twisted-wire pair
[data (+) and data (-)] network. The information or messages that can be communicated on these wires
consists of commands, status or data. The advantage of using multiplexing is to reduce the weight of the
vehicle by reducing the number of redundant components and electrical wiring.
The vehicle has 2 module communication networks which are connected to the Data Link Connector (DLC),
located under the instrument panel:
• High Speed Controller Area Network (HS-CAN)

• Medium Speed Controller Area Network (MS-CAN)
Network Topology
Termination
Module Name Network Type Module
4X4 control module (if equipped) HS-CAN No
ABS module HS-CAN No
Accessory Protocol Interface Module (APIM) (if equipped) HS-CAN No
MS-CAN No
Audio Front Control Module (ACM) MS-CAN No
Audio Digital Signal Processing (DSP) module (if equipped) MS-CAN No
Driver Door Module (DDM) (if equipped) MS-CAN No
Driver Seat Module (DSM) (if equipped) MS-CAN No
Dual Climate Controlled Seat Module (DCSM) (if equipped) MS-CAN No
Front Controls Interface Module (FCIM) MS-CAN No
Front Display Interface Module (FDIM) MS-CAN No
Communications Network 6211

Global Positioning System Module (GPSM) (if equipped) MS-CAN No

Headlamp Control Module (HCM) (if equipped) HS-CAN No
HVAC module (if equipped) MS-CAN No
Interior Lighting Control Module (ILCM) (if equipped) MS-CAN No
Instrument Panel Cluster (IPC) (gateway module) HS-CAN Yes
MS-CAN Yes
Occupant Classification System Module (OCSM) HS-CAN No
Parking Aid Module (PAM) (if equipped) MS-CAN No
Power Steering Control Module (PSCM) (if equipped) HS-CAN No
PCM HS-CAN Yes
Restraints Control Module (RCM) HS-CAN No
Smart Junction Box (SJB) MS-CAN Yes
Side Obstacle Detection Control Module - Left (SOD-L) (if equipped) MS-CAN No
Side Obstacle Detection Control Module - Right (SOD-R) (if MS-CAN No
equipped)
Transmission Control Module (TCM) (if equipped) HS-CAN No
Network Termination
The CAN uses network termination to improve communication reliability. Termination modules are located at
both ends of the network. As network messages are broadcast in the form of voltage signals, the network
voltage signals are stabilized by the termination resistors.
Each termination module has an internal 120 ohm resistor that bridges across the positive and negative bus
connection. With two 120 ohm resistors located in a parallel circuit configuration, the total network
impedance, or total resistance, is 60 ohms.
Network termination improves bus message reliability by:
• stabilizing bus voltage.

• eliminating electrical interference.
Gateway Module
The IPC is the gateway module, translating messages on the HS-CAN to MS-CAN and vice versa. This
allows a message to be distributed throughout both networks. The IPC is the only module on this vehicle that
has this ability.
Network Topology 6212


Communications Network - Hybrid
Multiplexing is a method of sending 2 or more signals simultaneously over a single circuit. Multiplexing is
used to allow 2 or more electronic modules (nodes) to communicate simultaneously over a twisted-wire pair
[data (+) and data (-)] network. The information or messages that can be communicated on these wires
consists of commands, status or data. The advantage of using multiplexing is to reduce the weight of the
vehicle by reducing the number of redundant components and electrical wiring.
The vehicle has 2 module communication networks which are connected to the Data Link Connector (DLC),
located under the instrument panel:
• High Speed Controller Area Network (HS-CAN)

• Medium Speed Controller Area Network (MS-CAN)
Network Topology
Termination
Module Name Network Type Module
ABS module HS-CAN No
Accessory Protocol Interface Module (APIM) (if equipped) HS-CAN No/No
MS-CAN
Air Conditioning Compressor Module (ACCM) HS-CAN No
Audio Front Control Module (ACM) MS-CAN No
Audio Digital Signal Processing (DSP) module (if equipped) MS-CAN No
Battery Energy Control Module (BECM) HS-CAN Yes
DC to DC Converter Control Module (DC/DC) HS-CAN No
Driver Door Module (DDM) (if equipped) MS-CAN No
Dual Climate Controlled Seat Module (DCSM) (if equipped) MS-CAN No
Driver Seat Module (DSM) (if equipped) MS-CAN No
Communications Network - Hybrid 6214

Front Controls Interface Module (FCIM) MS-CAN No

Front Display Interface Module (FDIM) MS-CAN No
Global Positioning System Module (GPSM) (if equipped) MS-CAN No
Headlamp Control Module (HCM) (if equipped) HS-CAN No
HVAC module (if equipped) MS-CAN No
Interior Lighting Control Module (ILCM) (if equipped) MS-CAN No
Instrument Panel Cluster (IPC) (gateway module) HS-CAN No/Yes
MS-CAN
Occupant Classification System Module (OCSM) HS-CAN No
Parking Aid Module (PAM) (if equipped) MS-CAN No
Power Steering Control Module (PSCM) HS-CAN No
PCM HS-CAN Yes
Restraints Control Module (RCM) HS-CAN No
Smart Junction Box (SJB) MS-CAN Yes
Side Obstacle Detection Control Module - Left (SOD-L) (if equipped) MS-CAN No
Side Obstacle Detection Control Module - Right (SOD-R) (if MS-CAN No
equipped)
Transmission Control Module (TCM) HS-CAN No
Network Termination
The CAN uses network termination to improve communication reliability. Termination modules are located at
both ends of the network. Each termination module has an internal 120 ohm resistor that bridges across the
positive and negative network circuit. With two 120 ohm resistors located in a parallel circuit configuration,
the total network impedance, or total resistance, is 60 ohms.
Network termination improves bus message reliability by:
• stabilizing bus voltage.

• eliminating electrical interference.
Gateway Module
The IPC is the gateway module, translating messages on the HS-CAN to MS-CAN and vice versa. This
allows a message to be distributed throughout both networks. The IPC is the only module on this vehicle that
has this ability.


Communications Network
Special Tool(s)


Flex Probe Kit
Both the High Speed Controller Area Network (HS-CAN) and the Medium Speed Controller Area Network
(MS-CAN) use an unshielded twisted-pair cable of data (+) and data (-) circuits. The HS-CAN operates at a
maximum data transfer speed of 500 Kbps and is designed for applications in which modules must respond as
rapidly as required by the driver or needed by the process being controlled. The MS-CAN operates at a
maximum data transfer speed of 125 Kbps for bus messages and is designed for general information transfer.
High Speed Controller Area Network (HS-CAN) Modules
The following modules are on the HS-CAN :
• 4X4 control module (if equipped)

• ABS module
• Accessory Protocol Interface Module (APIM) (if equipped)
• Air Conditioning Compressor Module (ACCM) (Hybrid only)
• Battery Energy Control Module (BECM) (Hybrid only)
• DC to DC Converter Control Module (DC/DC) (Hybrid only)
• Headlamp Control Module (HCM) (if equipped)
• Instrument Panel Cluster (IPC) (gateway module)
• Occupant Classification System Module (OCSM)
• PCM
• Power Steering Control Module (PSCM) (if equipped)
• Restraints Control Module (RCM)
• Transmission Control Module (TCM) (if equipped)
Medium Speed Controller Area Network (MS-CAN) Modules
The following modules are on the MS-CAN :
• Accessory Protocol Interface Module (APIM) (if equipped)

• Audio Front Control Module (ACM)
Communications Network 6217

• Audio Digital Signal Processing (DSP) module (if equipped)
• Driver Door Module (DDM) (if equipped)
• Driver Seat Module (DSM) (if equipped)
• Dual Climate Controlled Seat Module (DCSM) (if equipped)
• Global Positioning System Module (GPSM) (if equipped)
• HVAC module (if equipped)
• Interior Lighting Control Module (ILCM) (if equipped)
• Instrument Panel Cluster (IPC) (gateway module)
• Parking Aid Module (PAM) (if equipped)
• Side Obstacle Detection Control Module - Left (SOD-L) (if equipped)
• Side Obstacle Detection Control Module - Right (SOD-R) (if equipped)
Controller Area Network (CAN) Fault Tolerance
NOTE: The oscilloscope traces below are from the IDS oscilloscope taken using the IDS pre-configured
CAN settings. The traces are for both data (+) and data (-) taken simultaneously (2-channel) at a sample rate
of 1 mega-sample per second (1MS/s) or greater.
Traces below are viewed at 500mV per division (vertical axis) and 20 microseconds (20µ) per division
(horizontal axis). Readings taken with a different oscilloscope vary from those shown. Compare any suspect
readings to a known good vehicle.
Normal CAN Operation
The data (+) and data (-) circuits are each regulated to approximately 2.5 volts during neutral or rested
network traffic. As messages ae sent on the data (+) circuit, voltage is increased by approximately 1.0 volt.
Inversely, the data (-) circuit is reduced by approximately 1.0 volt when a message is sent.
Successful communication of a message can usually be identified by the slight spike at the end of a message
transmission. Any signals that are significantly different than the normal CAN waveform may cause network
DTCs (U-codes) to set or may cause a complete network outage.
CAN Circuits Shorted Together
Normal CAN Operation 6218

In the event that the data (+) and data (-) circuits become shorted together, the signal stays at base voltage
(2.5V) continuously and all communication capabilities are lost.
CAN (+) Circuit Shorted To Ground
In the event that the data (+) circuit becomes shorted to ground, both the data (+) and data (-) circuits are
pulled low (0V) and all communication capabilities are lost.
CAN (-) Circuit Shorted To Ground
In the event that the data (-) circuit becomes shorted to ground, the data (-) circuit is pulled low (0V) and the
data (+) circuit reaches near-normal peak voltage (3.0V) during communication but falls to 0V instead of
CAN Circuits Shorted Together 6219

normal base voltage (2.5V). Communication may continue but at a degraded level.
CAN (+) Circuit Shorted To Battery Voltage
In the event that the data (+) circuit becomes shorted to battery voltage, the data (+) circuit is pulled high
(12V) and the data (-) circuit falls to abnormally high voltage (above 5V) during communication and reaches
battery voltage (12V) for peak voltage. Communication may continue but at a degraded level.
CAN (-) Circuit Shorted To Battery Voltage
In the event that the data (-) circuit becomes shorted to battery voltage, both the data (+) and data (-) circuits
are pulled high (12V) and all communication capabilities are lost.
CAN Circuit Signal Corruption
CAN (-) Circuit Shorted To Ground 6220

Rhythmic oscillations, inductive spikes or random interference can disrupt the network communications. The
corruption signal source may be outside electrical interference such as motors or solenoids or internal
interference generated from a module on the network. In some cases, an open in either the data (+) or data (-)
circuit to a network module may cause the module to emit interference on the one circuit which is still
connected. The trace shown is an example of a "sawtooth" pattern transmitted from a module with one open
network circuit.
Other corruptions may be present when a module is intermittently powered up and down. The module on
power up may initiate communication out of sync with other modules on the network causing momentary
communication outages.
Controller Area Network (CAN) Multiplex Messages
Modules on the CAN utilize simultaneous communication of 2 or more messages on the same network
circuits. The following chart summarizes the messages sent and received on the network.
CAN Module Communication Message Chart - Gasoline Engine
NOTE: This chart describes the specific HS-CAN and MS-CAN messages broadcast by each module, and the
module(s) that receive the message.
Originating Network Receiving

Broadcast Message Module Type Module(s)
4X4 indicator status 4X4 control HS-CAN
module • IPC
4X4 mode 4X4 control HS-CAN
module • ABS
module
4X4 warning indicator request 4X4 control HS-CAN
module • IPC
A/C clutch engagement request HVAC module MS-CAN
• IPC
A/C clutch engagement request (gateway) IPC HS-CAN
• PCM
A/C clutch engagement status PCM HS-CAN
CAN Circuit Signal Corruption 6221

• IPC
A/C clutch engagement status (gateway) IPC HS-CAN
• HVAC
module
A/C recirculation mode request PCM HS-CAN
• IPC
A/C recirculation mode request (gateway) IPC MS-CAN
• HVAC
module
ABS event in progress ABS module HS-CAN
• PCM
• RCM
• TCM
ABS Roll Stability Control (RSC®) chime ABS module HS-CAN
malfunction status • IPC
ABS warning indicator request ABS module HS-CAN
• IPC
• RCM
Accelerator pedal position PCM HS-CAN
• 4X4
control
module
• ABS
module
• TCM
Accelerometer and yaw sensor data HS-CAN
• HCM
ABS module
• IPC
• PSCM
Accelerometer and yaw sensor data (gateway) IPC MS-CAN
• ACM
• GPSM
• HCM
Accessory delay status SJB MS-CAN
• APIM
• ACM
• FCIM
• FDIM
• ILCM
Airbag deployment eCall confirmation APIM HS-CAN
• RCM
Airbag deployment eCall notification RCM HS-CAN
• APIM
Airbag deployment event data record PCM HS-CAN
• RCM
Airbag deployment status RCM HS-CAN
• IPC
• OCSM
• PCM
Airbag deployment status (gateway) IPC MS-CAN
• SJB

Airbag warning indicator request RCM HS-CAN • IPC

Airbag warning indicator status IPC HS-CAN
• RCM
Ambient temperature, inferred PCM HS-CAN
• IPC
Ambient temperature, inferred (gateway) IPC MS-CAN
• SJB
Autolamp delay command IPC MS-CAN
• SJB
Autolamp delay status SJB MS-CAN
• IPC
Autolock command IPC MS-CAN
• SJB
Autolock status SJB MS-CAN
• IPC
Auto-unlock command IPC MS-CAN
• SJB
Auto-unlock status SJB MS-CAN
• IPC
Average fuel economy data IPC MS-CAN
• ACM
Average fuel economy reset request (with navigation ACM MS-CAN
ACM ) • IPC
Axle ratio PCM HS-CAN
• ABS
module
• IPC
Axle ratio (gateway) IPC MS-CAN
• SJB
Barometric pressure PCM HS-CAN
• IPC
• TCM
Barometric pressure (gateway) IPC MS-CAN
• SJB
Belt-Minder® warning status RCM HS-CAN
• IPC
Belt-Minder® warning status (gateway) IPC MS-CAN
• ACM
Belt-Minder® programming request RCM HS-CAN
• IPC
Brake (red) warning indicator request ABS module HS-CAN
• IPC
• RCM
Brake fluid level low SJB MS-CAN
• IPC
Brake lamp switch status PCM HS-CAN
• 4X4
control
module

• ABS
module
• TCM
Charging system status PCM HS-CAN
• IPC
Charging system warning indicator request PCM HS-CAN
• IPC
• PSCM
Climate controlled seat command HVAC module MS-CAN
• DCSM
Climate controlled seat status DCSM MS-CAN
• HVAC
module
Compass display data IPC MS-CAN
• FDIM
Compass zone and calibration status IPC MS-CAN
• FDIM
Door ajar status SJB MS-CAN
• IPC
Driver door lock command SJB MS-CAN
• DDM
Driver door lock cylinder status DDM MS-CAN
• SJB
Driver door lock switch status DDM MS-CAN
• SJB
Easy entry/exit command IPC MS-CAN
• DSM
Easy entry/exit status DSM MS-CAN
• IPC
Engine coolant temperature PCM HS-CAN
• 4X4
control
module
• IPC
• TCM
Engine coolant temperature (gateway) IPC MS-CAN
• HVAC
module
Engine fail-safe cooling mode status PCM HS-CAN
• IPC
Engine fail-safe Electronic Throttle Control (ETC) PCM HS-CAN
status • TCM
Engine fail-safe ETC warning indicator request PCM HS-CAN
• IPC
Engine load percentage PCM HS-CAN
• TCM
Engine MIL request PCM HS-CAN
• IPC
Engine off timer PCM HS-CAN

• 4X4
control
module
• IPC
Engine off timer (gateway) IPC MS-CAN
• HVAC
module
Engine RPM PCM HS-CAN
• 4X4
control
module
• ABS
module
• IPC
• PSCM
• TCM
Engine RPM (gateway) IPC MS-CAN
• DCSM
• HVAC
module
Engine RPM minimum request PCM HS-CAN
• TCM
Engine throttle position PCM HS-CAN
• TCM
Engine torque data PCM HS-CAN
• TCM
Engine torque data PCM HS-CAN
• ABS
module
• APIM
• TCM
Engine torque reduction request TCM HS-CAN
• PCM
Engine torque reduction request ABS module HS-CAN
• PCM
Engine torque transfer request ABS module HS-CAN
• 4X4
control
module
Engine type PCM HS-CAN
• ABS
module
• IPC
Engine type (gateway) IPC MS-CAN
• SJB
English/metric display (with navigation ACM ) ACM MS-CAN
• IPC
English/metric mode IPC MS-CAN
• ACM
• HVAC
module

ePRNDL mode IPC HS-CAN • PCM

• TCM
FCIM button press data FCIM MS-CAN
• ACM
• APIM
• Audio DSP
module
• IPC
Fuel cap off indicator request PCM HS-CAN
• IPC
Fuel flow data PCM HS-CAN
• APIM
• IPC
Fuel level (instant) IPC HS-CAN
• PCM
Fuel level status IPC MS-CAN
• ACM
Fuel level status IPC HS-CAN
• APIM
Fuel pump cutoff request RCM HS-CAN
• PCM
Headlamp high beam indicator request SJB MS-CAN
• IPC
Headlamp high beam indicator request (gateway) IPC HS-CAN
• HCM
Headlamp low beam status SJB MS-CAN
• IPC
Headlamp low beam status (gateway) IPC HS-CAN
• HCM
Headlamps on warning chime command SJB MS-CAN
• IPC
HVAC button status FCIM MS-CAN
• ACM
• HVAC
module
HVAC button status, navigation ACM ACM MS-CAN
• HVAC
module
HVAC indicator status HVAC module MS-CAN
• ACM
• FCIM
HVAC module display data HVAC module MS-CAN
• ACM
• FDIM
HVAC voice request ACM MS-CAN
• HVAC
module
Ignition key type IPC HS-CAN
• PCM

• ABS
module
• RCM
Ignition key type IPC MS-CAN
• ACM
Ignition switch position SJB MS-CAN
• ACM
• APIM
• Audio DSP
module
• DCSM
• DDM
• DSM
• FCIM
• FDIM
• GPSM
• HVAC
module
• ILCM
• IPC
• PAM
• SOD-R
• SOD-L
Ignition switch position (gateway) IPC HS-CAN
• 4X4
control
module
• ABS
module
• HCM
• PCM
• TCM
IKT programming request IPC MS-CAN
• SJB
IKT programming status SJB MS-CAN
• IPC
Instrument illumination level SJB MS-CAN
• ACM
• APIM
• FCIM
• FDIM
• HVAC
module
• ILCM
• IPC
• SOD-L
• SOD-R
Interior courtesy lamp battery saver status SJB MS-CAN
• ILCM
Interior courtesy lamp delay status SJB MS-CAN
• ILCM
Interior courtesy lamp door status SJB MS-CAN

• ILCM
Interior courtesy lamp illuminated entry status SJB MS-CAN
• ILCM
Key fob or Integrated Keyhead Transmitter (IKT) SJB MS-CAN
button status • DSM
Key fob or IKT ID SJB MS-CAN
• DSM
Key-in-ignition status SJB MS-CAN
• APIM
• DCSM
• DSM
• ILCM
• IPC
Key-in-ignition warning chime command SJB MS-CAN
• IPC
Keypad button status SJB MS-CAN
• DSM
Keypad ID SJB MS-CAN
• DSM
Low odometer status IPC MS-CAN
• HVAC
module
• SJB
Memory cancel command DSM MS-CAN
• DDM
Memory command DSM MS-CAN
• DDM
Memory set switch status DDM MS-CAN
• DSM
Mirror manual override DDM MS-CAN
• DSM
Navigation rolling wheel count ABS module HS-CAN
• IPC
Navigation rolling wheel count (gateway) IPC MS-CAN
• ACM
• APIM
• GPSM
Occupant Classification System (OCS) calibration OCSM HS-CAN
data • RCM
OCS fault status OCSM HS-CAN
• RCM
OCS object entrapped message request OCSM HS-CAN
• IPC
OCS sensor data OCSM HS-CAN
• IPC
• RCM
OCS sensor data (gateway) IPC MS-CAN
• SJB
OCS serial number OCSM HS-CAN

• RCM
Odometer rolling count PCM HS-CAN
• APIM
• IPC
Output Shaft Speed (OSS) TCM HS-CAN
• PCM
Park brake chime request SJB MS-CAN
• IPC
Park brake status SJB MS-CAN
• ACM
• IPC
Park brake status (gateway) IPC HS-CAN
• 4X4
control
module
• PCM
Park lamp status SJB MS-CAN
• ACM
• FCIM
• HVAC
module
• ILCM
• IPC
• SOD-L
• SOD-R
Parking aid enabled command IPC MS-CAN
• PAM
Parking aid enabled status PAM MS-CAN
• IPC
Parking aid fault status PAM MS-CAN
• IPC
Parking aid front warning command IPC MS-CAN
• PAM
Parking aid front warning status PAM MS-CAN
• IPC
Parking aid sounder volume cutback request PAM MS-CAN
• ACM
Passenger mirror switch status DDM MS-CAN
• DSM
Passenger seat belt buckle status RCM HS-CAN
• OCSM
Passive Anti-Theft System (PATS) security data IPC HS-CAN
• PCM
PATS security data PCM HS-CAN
• IPC
PATS security data IPC MS-CAN
• SJB
Perimeter alarm chime request SJB MS-CAN
• IPC
PSCM fault status PSCM HS-CAN

• IPC
RCM serial number RCM HS-CAN
• ABS
module
• OCSM
Reverse mirror command IPC MS-CAN
• DSM
Reverse mirror status DSM MS-CAN
• IPC
Seat belt indicator request RCM HS-CAN
• IPC
Seat belt warning chime request RCM HS-CAN
• IPC
Seat belt warning chime status IPC HS-CAN
• RCM
Side obstacle detection cross traffic alert SOD-L MS-CAN
• IPC
• PAM
Side obstacle detection cross traffic alert SOD-R MS-CAN
• IPC
• PAM
Side obstacle detection cross traffic command IPC MS-CAN
• SOD-L
• SOD-R
Side obstacle detection cross traffic status SOD-L MS-CAN
• IPC
Side obstacle detection cross traffic status SOD-R MS-CAN
• IPC
Side obstacle detection enabled status IPC MS-CAN
• SOD-L
• SOD-R
Side obstacle detection system status SOD-L MS-CAN
• IPC
Side obstacle detection system status SOD-R MS-CAN
• IPC
Speed control deactivation request ABS module HS-CAN
• PCM
Speed control indicator status PCM HS-CAN
• 4X4
control
module
• IPC
Speed control status PCM HS-CAN
• TCM
Stability control disable switch status IPC HS-CAN
• ABS
module
• PCM
Stability control event in progress ABS module HS-CAN
• PCM

• RCM
Stability control indicator status ABS module HS-CAN
• IPC
• RCM
Stability control present ABS module HS-CAN
• TCM
Steering wheel angle PSCM HS-CAN
• 4X4
control
module
• ABS
module
• HCM
• RCM
Steering wheel angle offset ABS module HS-CAN
• PSCM
Target RPM request TCM HS-CAN
• PCM
TCM desired converter clutch mode PCM HS-CAN
• TCM
TCM desired gear PCM HS-CAN
• TCM
Tire revolutions per mile PCM HS-CAN
• ABS
module
• IPC
• TCM
Tire revolutions per mile (gateway) IPC MS-CAN
• SJB
Tire size information ABS module HS-CAN
• IPC
• PCM
Tire size information (gateway) IPC MS-CAN
• APIM
Torque transfer percent command 4X4 control HS-CAN
module • ABS
module
TPMS indicator command SJB MS-CAN
• APIM
• IPC
TPMS sensor status SJB MS-CAN
• APIM
TPMS system status SJB MS-CAN
• APIM
• IPC
Traction control event in progress ABS module HS-CAN
• PCM
• RCM
Transmission ePRNDL display PCM HS-CAN
• IPC

Transmission ePRNDL display TCM HS-CAN • IPC

Transmission forward clutch neutral idle status TCM HS-CAN
• PCM
Transmission gear actual PCM HS-CAN
• 4X4
control
module
• ABS
module
Transmission gear actual TCM HS-CAN
• 4X4
control
module
• ABS
module
Transmission malfunction indicator request TCM HS-CAN
• PCM
Transmission overdrive cancel status PCM HS-CAN
• IPC
Transmission overdrive cancel status TCM HS-CAN
• IPC
Transmission select shift present IPC HS-CAN
• TCM
Transmission selector (PRNDL) status PCM HS-CAN
• ABS
module
• HCM
• IPC
• RCM
Transmission selector (PRNDL) status TCM HS-CAN
• ABS
module
• HCM
• IPC
• RCM
Transmission selector (PRNDL) status (gateway) IPC MS-CAN
• ACM
• APIM
• DSM
• GPSM
• PAM
• SJB
• SOD-L
• SOD-R
Transmission shift in progress TCM HS-CAN
• ABS
• PCM
Transmission shift mode PCM HS-CAN
• IPC
Transmission shift mode TCM HS-CAN
• IPC

Transmission temperature TCM HS-CAN • PCM

Turbine Shaft Speed (TSS) TCM HS-CAN
• PCM
Turn signal command SJB MS-CAN
• IPC
Vehicle speed PCM HS-CAN
• HCM
• IPC
• TCM
Vehicle speed (gateway) IPC MS-CAN
• ACM
• Audio DSP
module
• GPSM
• HVAC
module
• PAM
• SJB
• SOD-L
• SOD-R
VIN information PCM HS-CAN
• 4X4
control
module
• ABS
module
• IPC
• RCM
• TCM
VIN information (gateway) IPC MS-CAN
• APIM
• ACM
• HVAC
module
• SJB
Wheel speed data ABS module HS-CAN
• 4X4
control
module
• PCM
• TCM
CAN Module Communication Message Chart - Hybrid
NOTE: This chart describes the specific HS-CAN and MS-CAN messages broadcast by each module, and the
module(s) that receive the message.
Originating Network Receiving

Broadcast Message Module Type Module(s)

A/C cabin air temperature HVAC module MS-CAN • IPC

A/C cabin air temperature (gateway) IPC HS-CAN
• BECM
• PCM
A/C compressor enabled status ACCM HS-CAN
• PCM
A/C compressor engagement request HVAC module MS-CAN
• IPC
A/C compressor engagement request (gateway) IPC HS-CAN
• PCM
A/C compressor maximum power consumption PCM HS-CAN
allowed • ACCM
A/C compressor power consumption ACCM HS-CAN
• PCM
A/C compressor speed ACCM HS-CAN
• PCM
A/C compressor status PCM HS-CAN
• ACCM
• IPC
A/C compressor status (gateway) IPC MS-CAN
• HVAC
module
A/C compressor target speed PCM HS-CAN
• ACCM
A/C evaporator temperature HVAC module MS-CAN
• IPC
A/C evaporator temperature (gateway) IPC HS-CAN
• PCM
A/C recirculation door status HVAC module MS-CAN
• IPC
A/C recirculation door status (gateway) IPC HS-CAN
• BECM
• PCM
ABS braking active status ABS module HS-CAN
• PCM
• TCM
ABS event in progress ABS module HS-CAN
• PCM
• RCM
ABS fault status ABS module HS-CAN
• PCM
ABS Roll Stability Control (RSC®) chime ABS module HS-CAN
malfunction status • IPC
ABS self-test in operation status ABS module HS-CAN
• PCM
ABS warning indicator request ABS module HS-CAN
• IPC
• RCM

Accelerometer and yaw sensor dataABS moduleHS-CAN
• IPC
• PSCM
Accelerometer and yaw sensor data (gateway)IPCMS-CAN
• ACM
• GPSM
Accessory delay statusSJBMS-CAN
• APIM
• ACM
• FCIM
• FDIM
• ILCM
Airbag deployment eCall confirmationAPIMHS-CAN
• RCM
Airbag deployment eCall notificationRCMHS-CAN
• APIM
Airbag deployment event data recordPCMHS-CAN
• RCM
Airbag deployment statusRCMHS-CAN
• IPC
• OCSM
• PCM
Airbag deployment status (gateway)IPCMS-CAN
• SJB
Airbag warning indicator requestRCMHS-CAN
• IPC
Airbag warning indicator statusIPCHS-CAN
• RCM
Ambient temperatureHVAC moduleMS-CAN
• ACM
• IPC
Ambient temperature (gateway)IPCHS-CAN

• PCM
Ambient temperature, inferredPCMHS-CAN
• ABS module
• ACCM
• BECM
• DC/DC
• IPC
• TCM
Autolamp delay commandIPCMS-CAN
• SJB
Autolamp delay statusSJBMS-CAN
• IPC
Autolock commandIPCMS-CAN
• SJB
Autolock statusSJBMS-CAN
• IPC
Auto-unlock commandIPCMS-CAN
• SJB
Auto-unlock statusSJBMS-CAN
• IPC
Average fuel economy dataIPCMS-CAN
• ACM
Average fuel economy reset request (navigation)ACMMS-CAN
• IPC
Barometric pressurePCMHS-CAN
• IPC
Barometric pressure (gateway)IPCMS-CAN
• HVAC module
• SJB
Belt-Minder® warning statusRCMHS-CAN

• IPC
Belt-Minder® warning status (gateway)IPCMS-CAN
• ACM
Belt-Minder® programming requestRCMHS-CAN
• IPC
Brake (red) warning indicator requestABS moduleHS-CAN
• IPC
• RCM
Brake fluid level lowSJBMS-CAN
• IPC
Brake lamp illuminated statusABS moduleHS-CAN
• IPC
Brake pedal positionABS moduleHS-CAN
• PCM
Brake system type configurationABS moduleHS-CAN
• IPC
Brake vacuum requestABS moduleHS-CAN
• PCM
Climate control mode statusHVAC moduleMS-CAN
• IPC
Climate control mode status (gateway)IPCHS-CAN
• PCM
Compass display dataIPCMS-CAN
• FDIM
Compass zone and calibration statusIPCMS-CAN
• FDIM
Door ajar statusSJBMS-CAN
• IPC

Door lock statusSJBMS-CAN
• IPC
Engine air inlet temperaturePCMHS-CAN
• BECM
Engine coolant temperaturePCMHS-CAN
• BECM
• IPC
• TCM
Engine coolant temperature (gateway)IPCMS-CAN
• HVAC module
Engine fail-safe cooling mode statusPCMHS-CAN
• IPC
Engine Malfunction Indicator Lamp (MIL) requestTCMHS-CAN
• PCM
Engine MIL requestPCMHS-CAN
• IPC
Engine MIL requestBECMHS-CAN
• PCM
Engine off timerPCMHS-CAN
• IPC
Engine off timer (gateway)IPCMS-CAN
• HVAC module
Engine RPMPCMHS-CAN
• ABS module
• BECM
• IPC
Engine RPM (gateway)IPCMS-CAN
• APIM
• HVAC module
Engine RPM desiredPCMHS-CAN

• TCM
Engine run/stop statusPCMHS-CAN
• TCM
Engine throttle positionPCMHS-CAN
• BECM
• TCM
Engine torque dataPCMHS-CAN
• ABS
• IPC
• TCM
Engine torque desiredPCMHS-CAN
• IPC
• TCM
Engine torque reduction requestABS moduleHS-CAN
• PCM
Engine typePCMHS-CAN
• IPC
Engine type (gateway)IPCMS-CAN
• SJB
English/metric display (navigation)ACMMS-CAN
• IPC
English/metric modeIPCMS-CAN
• ACM
• HVAC module
English/metric modeIPCHS-CAN
• PCM
FCIM button press dataFCIMMS-CAN
• ACM
• APIM
• IPC

Fuel cap off indicator requestPCMHS-CAN
• IPC
Fuel cutoff requestTCMHS-CAN
• PCM
Fuel door open statusPCMHS-CAN
• IPC
Fuel economy historyIPCMS-CAN
• ACM
Fuel level (instant)IPCHS-CAN
• PCM
Fuel level statusIPCMS-CAN
• ACM
Fuel level statusIPCHS-CAN
• APIM
Fuel pump cutoff requestRCMHS-CAN
• BECM
• PCM
Headlamp high beam indicator requestSJBMS-CAN
• IPC
Headlamp low beam statusSJBMS-CAN
• IPC
Headlamps on warning chime commandSJBMS-CAN
• IPC
HVAC button statusFCIMMS-CAN
• ACM
• HVAC module
HVAC button status, navigation ACMACMMS-CAN
• HVAC module

HVAC indicator statusHVAC moduleMS-CAN
• ACM
• FCIM
HVAC module display dataHVAC moduleMS-CAN
• ACM
• FDIM
HVAC recirculation door overrideBECMHS-CAN
• IPC
HVAC recirculation door override (gateway)IPCMS-CAN
• HVAC module
HVAC recirculation door override (gateway)IPCMS-CAN
• HVAC module
HVAC voice requestACMMS-CAN
• HVAC module
Hybrid battery airflow volumeBECMHS-CAN
• IPC
Hybrid battery airflow volume (gateway)IPCMS-CAN
• HVAC module
Hybrid battery currentBECMHS-CAN
• IPC
• PCM
• TCM
Hybrid battery fault statusBECMHS-CAN
• PCM
Hybrid battery fault statusBECMHS-CAN
• PCM
Hybrid battery jumpstart active statusBECMHS-CAN
• PCM
Hybrid battery regeneration mode requestBECMHS-CAN

• PCM
Hybrid battery regeneration power dataBECMHS-CAN
• PCM
Hybrid battery state of charge dataBECMHS-CAN
• PCM
Hybrid battery state of charge display levelPCMHS-CAN
• IPC
Hybrid battery state of charge display level (gateway)IPCMS-CAN
• ACM
• HVAC module
Hybrid battery temperatureBECMHS-CAN
• IPC
• PCM
• TCM
Hybrid battery temperature (gateway)IPCMS-CAN
• HVAC module
Hybrid battery voltageBECMHS-CAN
• IPC
• PCM
• TCM
Hybrid brake regeneration faultABS moduleHS-CAN
• PCM
Hybrid brake torque requestABS moduleHS-CAN
• PCM
Hybrid charging system indicator requestDC/DCHS-CAN
• IPC
• PCM
• PSCM
Hybrid contactor control requestPCMHS-CAN
• TCM
Hybrid contactor statusBECMHS-CAN

• PCM
• TCM
Hybrid DC/DC system statusDC/DCHS-CAN
• BECM
• PCM
Hybrid DC/DC voltage statusDC/DCHS-CAN
• BECM
• IPC
• PCM
Hybrid engine load percentagePCMHS-CAN
• BECM
• TCM
Hybrid engine sync counter cylinder IDPCMHS-CAN
• TCM
Hybrid generator coil temperatureTCMHS-CAN
• PCM
Hybrid generator error statusTCMHS-CAN
• PCM
Hybrid generator inverter temperatureTCMHS-CAN
• PCM
Hybrid generator modePCMHS-CAN
• TCM
Hybrid generator speedTCMHS-CAN
• IPC
• PCM
Hybrid generator torque commandTCMHS-CAN
• IPC
• PCM
Hybrid global snapshot timerBECMHS-CAN
• ACCM
• ABS module
• DC/DC

• IPC
• PCM
• TCM
Hybrid hazard warning indicator requestBECMHS-CAN
• IPC
Hybrid hazard warning indicator requestTCMHS-CAN
• IPC
Hybrid hazard warning indicator requestPCMHS-CAN
• IPC
Hybrid heater pump requestHVAC moduleMS-CAN
• IPC
Hybrid heater pump request (gateway)IPCHS-CAN
• PCM
Hybrid heater pump statusPCMHS-CAN
• IPC
Hybrid heater pump status (gateway)IPCMS-CAN
• HVAC module
Hybrid inverter voltageTCMHS-CAN
• BECM
• PCM
Hybrid minimum engine speed requestTCMHS-CAN
• PCM
Hybrid motor coil temperatureTCMHS-CAN
• PCM
Hybrid motor coolant over temperature warningPCMHS-CAN
• IPC
Hybrid motor coolant temperaturePCMHS-CAN
• DC/DC
• TCM

Hybrid motor error statusTCMHS-CAN
• PCM
Hybrid motor inverter temperatureTCMHS-CAN
• PCM
Hybrid motor torque commandTCMHS-CAN
• IPC
• PCM
Hybrid motor torque dataTCMHS-CAN
• PCM
Hybrid odometer countTCMHS-CAN
• PCM
Hybrid operating modePCMHS-CAN
• BECM
• TCM
Hybrid powertrain efficiency glow percentagePCMHS-CAN
• IPC
Hybrid powertrain malfunction indicator requestBECMHS-CAN
• IPC
Hybrid powertrain malfunction indicator requestTCMHS-CAN
• IPC
Hybrid powertrain malfunction indicator requestPCMHS-CAN
• IPC
Hybrid powertrain powerflow display dataPCMHS-CAN
• IPC
Hybrid powertrain powerflow display data (gateway)IPCMS-CAN
• ACM
• HVAC module
Hybrid powertrain powerflow display textPCMHS-CAN
• IPC

Hybrid powertrain powerflow display text (gateway)IPCMS-CAN
• ACM
• HVAC module
Hybrid powertrain status engine activePCMHS-CAN
• IPC
Hybrid powertrain status engine active (gateway)IPCMS-CAN
• ACM
• HVAC module
Hybrid powertrain status front axle activePCMHS-CAN
• IPC
Hybrid powertrain status front axle active (gateway)IPCMS-CAN
• ACM
• HVAC module
Hybrid powertrain status high voltage battery activePCMHS-CAN
• IPC
Hybrid powertrain status high voltage battery active (gateway)IPCMS-CAN
• ACM
• HVAC module
Hybrid powertrain status motor/generator activePCMHS-CAN
• IPC
Hybrid powertrain status motor/generator active (gateway)IPCMS-CAN
• ACM
• HVAC module
Hybrid ready light statusPCMHS-CAN
• ABS
• BECM
• DC/DC
• IPC
• PSCM
Hybrid transmission temperatureTCMHS-CAN
• PCM
Ignition key typeIPCHS-CAN

• PCM
• ABS module
• RCM
Ignition key typeIPCMS-CAN
• ACM
Ignition switch positionSJBMS-CAN
• ACM
• APIM
• FCIM
• FDIM
• GPSM
• HVAC module
Ignition switch position (gateway)IPCHS-CAN
• ABS module
• PCM
• TCM
• ACCM
• BECM
• DC/DC
Ignition switch positionSJBMS-CAN
• ILCM
• IPC
• PAM
• SOD-R
• SOD-L
IKT programming requestIPCMS-CAN
• SJB
IKT programming statusSJBMS-CAN
• IPC
Instrument illumination levelSJBMS-CAN
• ACM
• APIM
• FCIM
• FDIM
• HVAC module
• ILCM
• IPC
• SOD-L
• SOD-R

Interior courtesy lamp battery saver statusSJBMS-CAN
• ILCM
Interior courtesy lamp delay statusSJBMS-CAN
• ILCM
Interior courtesy lamp door statusSJBMS-CAN
• ILCM
Interior courtesy lamp illuminated entry statusSJBMS-CAN
• ILCM
Key-in-ignition statusSJBMS-CAN
• APIM
• ILCM
• IPC
Key-in-ignition warning chime commandSJBMS-CAN
• IPC
Low odometer statusIPCMS-CAN
• HVAC module
• SJB
MyKey maximum speed commandIPCHS-CAN
• PCM
MyKey volume commandIPCMS-CAN
• ACM
Navigation rolling wheel countABS moduleHS-CAN
• IPC
Navigation rolling wheel count (gateway)IPCMS-CAN
• ACM
• APIM
• GPSM
OCS calibration dataOCSMHS-CAN
• RCM
OCS fault statusOCSMHS-CAN

• RCM
OCS object entrapped message requestOCSMHS-CAN
• IPC
OCS sensor dataOCSMHS-CAN
• IPC
• RCM
OCS sensor data (gateway)IPCMS-CAN
• SJB
OCS serial numberOCSMHS-CAN
• RCM
Odometer rolling countPCMHS-CAN
• IPC
Park brake chime requestSJBMS-CAN
• IPC
Park brake statusSJBMS-CAN
• ACM
• IPC
Park brake status (gateway)IPCHS-CAN
• PCM
• ABS module
• IPC
Park lamp statusSJBMS-CAN
• FCIM
• HVAC module
• ILCM
• IPC
• SOD-L
• SOD-R
Parking aid enabled commandIPCMS-CAN
• PAM
Parking aid enabled statusPAMMS-CAN
• IPC

Parking aid fault statusPAMMS-CAN
• IPC
Parking aid front warning commandIPCMS-CAN
• PAM
Parking aid front warning statusPAMMS-CAN
• IPC
Parking aid sounder volume cutback requestPAMMS-CAN
• ACM
Passenger seat belt buckle statusRCMHS-CAN
• OCSM
Passive Anti-Theft System (PATS) security dataIPCHS-CAN
• TCM
PATS security dataTCMHS-CAN
• IPC
PATS security dataIPCMS-CAN
• SJB
Perimeter alarm chime requestSJBMS-CAN
• IPC
PSCM fault statusPSCMHS-CAN
• IPC
RCM serial numberRCMHS-CAN
• ABS module
• OCSM
Seat belt indicator requestRCMHS-CAN
• IPC
Seat belt warning chime requestRCMHS-CAN
• IPC
Seat belt warning chime statusIPCHS-CAN

• RCM
Side obstacle detection cross traffic alertSOD-LMS-CAN
• IPC
• PAM
Side obstacle detection cross traffic alertSOD-RMS-CAN
• IPC
• PAM
Side obstacle detection cross traffic commandIPCMS-CAN
• SOD-L
• SOD-R
Side obstacle detection cross traffic statusSOD-LMS-CAN
• IPC
Side obstacle detection cross traffic statusSOD-RMS-CAN
• IPC
Side obstacle detection enabled statusIPCMS-CAN
• SOD-L
• SOD-R
Side obstacle detection system statusSOD-LMS-CAN
• IPC
Side obstacle detection system statusSOD-RMS-CAN
• IPC
Speed control deactivation requestABS moduleHS-CAN
• PCM
Speed control indicator statusPCMHS-CAN
• IPC
Stability control event in progressABS moduleHS-CAN
• PCM
• RCM
Stability control indicator statusABS moduleHS-CAN
• IPC

• RCM
Stability control presentABS moduleHS-CAN
• IPC
Steering column torquePSCMHS-CAN
• IPC
Steering wheel anglePSCMHS-CAN
• ABS module
• RCM
Steering wheel angle offsetABS moduleHS-CAN
• PSCM
TCM error statusTCMHS-CAN
• PCM
Tire revolutions per milePCMHS-CAN
• ABS module
• IPC
• TCM
Tire size informationABS moduleHS-CAN
• IPC
Tire size information (gateway)IPCMS-CAN
• APIM
• GPSM
TPMS indicator commandSJBMS-CAN
• APIM
• IPC
TPMS sensor statusSJBMS-CAN
• APIM
TPMS system statusSJBMS-CAN
• APIM
• IPC
Traction control event in progressABS moduleHS-CAN

• IPC
• PCM
• RCM
Transmission selector (PRNDL) statusPCMHS-CAN
• ABS module
• BECM
• DC/DC
• IPC
• TCM
Transmission selector (PRNDL) status (gateway)IPCMS-CAN
• ACM
• APIM
• GPSM
• PAM
• SJB
• SOD-L
• SOD-R
Turn signal commandSJBMS-CAN
• IPC
Vehicle rolling directionPCMHS-CAN
• ABS module
Vehicle rolling direction confirmationABS moduleHS-CAN
• PCM
Vehicle speedTCMHS-CAN
• BECM
• IPC
• PCM
• PSCM
Vehicle speed (gateway)IPCMS-CAN
• ACM
• APIM
• GPSM
• HVAC module
• PAM
• SJB
• SOD-L
• SOD-R
VIN informationPCMHS-CAN

• ABS module
• IPC
• RCM
• TCM
• ACCM
• BECM
• DC/DC
VIN information (gateway)IPCMS-CAN
• APIM
• ACM
• HVAC module
• SJB
Wheel speed dataABS moduleHS-CAN
• PCM
• TCM

• If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.
Electrical
• BJB fuse(s):
♦ 12 (30A) (no communication with the DCSM )
♦ 16 (5A) (no communication with the TCM (3.5L only))
♦ 17 (10A) (no communication with the BECM (hybrid only))
♦ 19 (25A) (no communication with audio Digital Signal Processing (DSP) module
♦ 20 (20A) (no communication with the audio DSP module)
♦ 21 (20A) (no communication with the audio DSP module)
♦ 23 (10A) (no communication with the PCM, TCM (hybrid only))
♦ 32 (30A) (no communication with the DSM )
♦ 39 (10A) (no communication with the TCM (hybrid only))
♦ 40 (10A) (no communication with the PCM (hybrid only))
♦ 42 (10A) (no communication with the ABS module (gasoline engine only))
♦ 44 (10A) (no communication with the TCM (3.5L only))
♦ 46 (15A) (no communication with the PCM (gasoline engine only))
♦ 47 (10A) (no communication with the ABS module (hybrid only), ACCM (hybrid only),
DC/DC (hybrid only))

♦ 48 (20A) (no communication with the BECM (hybrid only))

• SJB fuse(s):
♦ 5 (10A) (no communication with the SJB )
♦ 11 (10A) (no communication with the 4X4 control module)
♦ 12 (7.5A) (no communication with the DDM )
♦ 13 (5A) (no communication with the APIM )
♦ 14 (10A) (no communication with the FCIM , FDIM , ILCM , GPSM )
♦ 15 (10A) (no communication with the HVAC module)
♦ 20 (15A) (no power to the scan tool)
♦ 26 (15A) (no communication with the IPC )
♦ 29 (5A) (no communication with the IPC )
♦ 32 (10A) (no communication with the RCM )
♦ 35 (10A) (no communication with the 4X4 control module, PAM , SOD-L , SOD-R )
♦ 39 (20A) (no communication with the ACM )
♦ 42 (10A) (no communication with the HCM , PSCM )
♦ 46 (7.5A) (no communication with the OCSM )
• DLC
• Wiring harness
3. Connect the scan tool to the Data Link Connector (DLC).

• NOTE: Make sure to use the latest scan tool software release.
NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and
ground from the DLC are provided to the VCM .
If the Integrated Diagnostic System (IDS) does not communicate with the VCM :
♦ Check the VCM connection to the vehicle.

♦ Check the scan tool connection to the VCM .
♦ GO to Pinpoint Test AF , to diagnose No Power To The Scan Tool.
4. Establish a scan tool session.

• NOTE: The scan tool will first attempt to communicate with the PCM, after establishing
communication with the PCM, the scan tool will then attempt to communicate with all other
modules on the vehicle.
If an IDS session cannot be established with the vehicle, ( IDS may state "No communication
can be established with the PCM"):
♦ Choose "NO" when the scan tool prompts whether or not to retry communication.
♦ Enter either a PCM part number, tear tag or calibration number to identify the vehicle
and start a session (the PCM part number and 4-character tear tag are printed on the
PCM label).
♦ GO to Pinpoint Test A , to diagnose The PCM Does Not Respond To The Scan Tool.

• If the network test passes, retrieve and record the continuous memory DTCs and proceed to
Step 6.
• If the network test fails, GO to Symptom Chart to diagnose the failed communication
network.
• If a module fails to communicate during the network test, GO to Symptom Chart .

6. Retrieve and review the DTCs.
• If the DTCs retrieved are related to the concern, go to DTC Charts. Follow the non-network
DTC diagnostics (B-codes, C-codes, P-codes) prior to the network DTC diagnostics
(U-codes). For all other DTCs, refer to the Diagnostic Trouble Code (DTC) Chart in Section
419-10 .
• If no DTCs related to the concern are retrieved, GO to Symptom Chart .
DTC Charts
NOTE: Network DTCs (U-codes) are often a result of intermittent concerns such as damaged wiring or low
battery voltage occurrences. Additionally, vehicle service procedures such as module reprogramming will
often set network DTCs. Replacing a module to resolve a network DTC is unlikely to resolve the concern. To
prevent repeat network DTC concerns, inspect all network wiring, especially connectors. Test the vehicle
battery, refer to Section 414-01 .
Communication Network DTC Chart
DTC Description Source Action

U0001 High Speed CAN Communication ABS The module could not communicate on the
Bus module network at a point in time. The fault is currently
not present. CLEAR the DTC. REPEAT the
network test with the scan tool.
U0001:88 High Speed CAN Communication ABS The module could not communicate on the
Bus: Bus Off module network at a point in time. The fault is currently
DC/DC network test with the scan tool.
HCM
PSCM
U0002:88 High Speed CAN Communication IPC The module could not communicate on the
Bus Performance: Bus Off network at a point in time. The fault is currently
U0011:88 Medium Speed CAN IPC The module could not communicate on the
Communication Bus Performance: network at a point in time. The fault is currently
Bus Off not present. CLEAR the DTC. REPEAT the
U0028:08 Vehicle Communication Bus A: RCM The module could not communicate on the
Bus Signal / Message Failures network at a point in time. The fault is currently
U0028:88 Vehicle Communication Bus A: OCSM The module could not communicate on the
Bus Off network at a point in time. The fault is currently
RCM not present. CLEAR the DTC. REPEAT the


U0073 Control Module Communication TCM The module could not communicate on the
Bus A Off network at a point in time. The fault is currently
U0074:00 Control Module Communication BECM Refer to Section 100-01 .
Bus B Off: No Sub Type
Information
U0100 Lost Communication With ECM 4X4 CLEAR the DTC. REPEAT the network test
/PCM control with the scan tool. If the DTC returns, GO to
module Pinpoint Test A .
ABS
module
TCM
U0100:00 Lost Communication With ECM ABS CLEAR the DTC. REPEAT the network test
/PCM "A": No Sub Type module with the scan tool. If the DTC returns, GO to
Information Pinpoint Test A .
ACCM
APIM
BECM
DC/DC
IPC
PSCM
RCM
U0100:87 Lost Communication With ECM HCM CLEAR the DTC. REPEAT the network test
/PCM "A": Missing Message with the scan tool. If the DTC returns, GO to
OCSM Pinpoint Test A .
TCM
(Hybrid)
U0101 Lost Communication With TCM ABS CLEAR the DTC. REPEAT the network test
module with the scan tool. If the DTC returns, GO to
Pinpoint Test G .
U0101:00 Lost Communication With TCM : BECM CLEAR the DTC. REPEAT the network test
No Sub Type Information with the scan tool. If the DTC returns, GO to
DC/DC Pinpoint Test G .
IPC
U0101:87 Lost Communication With TCM : HCM CLEAR the DTC. REPEAT the network test
Missing Message with the scan tool. If the DTC returns, GO to
Pinpoint Test G .
U0102:00 Lost Communication With Transfer IPC CLEAR the DTC. REPEAT the network test
Case Control Module: No Sub with the scan tool. If the DTC returns, GO to
Type Information Pinpoint Test H .

U010F:00 Lost Communication With Air IPC CLEAR the DTC. REPEAT the network test
Conditioning Control Module: No (Hybrid) with the scan tool. If the DTC returns, GO to
Sub Type Information Pinpoint Test K .
U0111:00 Lost Communication With Battery IPC CLEAR the DTC. REPEAT the network test
Energy Control Module "A": No (Hybrid) with the scan tool. If the DTC returns, GO to
Sub Type Information Pinpoint Test J .
U0111:87 Lost Communication With Battery TCM CLEAR the DTC. REPEAT the network test
Energy Control Module "A": (Hybrid) with the scan tool. If the DTC returns, GO to
Missing Message Pinpoint Test J .
U0114 Lost Communication With ABS CLEAR the DTC. REPEAT the network test
Four-Wheel Drive Clutch Control module with the scan tool. If the DTC returns, GO to
Module Pinpoint Test H .
U0114:00 Lost Communication With ABS CLEAR the DTC. REPEAT the network test
Four-Wheel Drive Clutch Control module with the scan tool. If the DTC returns, GO to
Module: No Sub Type Information Pinpoint Test H .
U0121 Lost Communication With 4X4 CLEAR the DTC. REPEAT the network test
Anti-Lock Brake System (ABS) control with the scan tool. If the DTC returns, GO to
Control Module module Pinpoint Test B .
U0121:00 Lost Communication With IPC CLEAR the DTC. REPEAT the network test
Anti-Lock Brake System (ABS) with the scan tool. If the DTC returns, GO to
Control Module: No Sub Type PSCM Pinpoint Test B .
Information
RCM
U0121:87 Lost Communication With HCM CLEAR the DTC. REPEAT the network test
Anti-Lock Brake System (ABS) with the scan tool. If the DTC returns, GO to
Control Module: Missing Message Pinpoint Test B .
U0126:87 Lost Communication With Steering HCM CLEAR the DTC. REPEAT the network test
Angle Sensor Module: Missing with the scan tool. If the DTC returns, GO to
Message Pinpoint Test D .
U0129:87 Lost Communication With Brake TCM CLEAR the DTC. REPEAT the network test
System Control Module: Missing (Hybrid) with the scan tool. If the DTC returns, GO to
Message Pinpoint Test B .
U0131:00 Lost Communication With Power IPC CLEAR the DTC. REPEAT the network test
Steering Control Module: No Sub with the scan tool. If the DTC returns, GO to
Type Information Pinpoint Test D .
U0131:87 Lost Communication With Power ABS CLEAR the DTC. REPEAT the network test
Steering Control Module: Missing module with the scan tool. If the DTC returns, GO to
Message Pinpoint Test D .
U0140 Lost Communication With Body ABS CLEAR the DTC. REPEAT the network test
Control Module ( GEM ) module with the scan tool. If the DTC returns, GO to
Pinpoint Test U .
ACM
DDM
DSM
FCIM
FDIM

PAM
ILCM
U0140:00 Lost Communication With Body ACM CLEAR the DTC. REPEAT the network test
Control Module ( GEM ): No Sub with the scan tool. If the DTC returns, GO to
Type Information APIM Pinpoint Test U .
Audio DSP
module
FCIM
GPSM
HVAC
module
IPC
U0151:00 Lost Communication With APIM CLEAR the DTC. REPEAT the network test
Restraints Control Module: No Sub with the scan tool. If the DTC returns, GO to
Type Information BECM Pinpoint Test E .
IPC
Restraints Control Module: module with the scan tool. If the DTC returns, GO to
Missing Message Pinpoint Test E .
OCSM
U0151:88 Lost Communication With ABS The module could not communicate on the
Restraints Control Module: Bus module network at a point in time. The fault is currently
Off not present. CLEAR the DTC. REPEAT the
U0154:00 Lost Communication With RCM CLEAR the DTC. REPEAT the network test
Restraints Occupant Classification with the scan tool. If the DTC returns, GO to
System Module: No Sub Type Pinpoint Test F .
Information
U0155 Lost Communication With 4X4 CLEAR the DTC. REPEAT the network test
Instrument Panel Cluster ( IPC ) control with the scan tool. If the DTC returns, GO to
Module module Pinpoint Test C .
ABS
module
ACM
DSM
FDIM
GPSM
PAM
SJB

U0155:00 Lost Communication With ACCM CLEAR the DTC. REPEAT the network test
Instrument Panel Cluster ( IPC ) with the scan tool. If the DTC returns, GO to
Control Module: No Sub Type ACM Pinpoint Test C .
Information
APIM
Audio DSP
module
BECM
DC/DC
HVAC
module
RCM
Instrument Panel Cluster ( IPC ) module with the scan tool. If the DTC returns, GO to
Control Module: Missing Message Pinpoint Test C .
HCM
U0159 Lost Communication With Parking ACM CLEAR the DTC. REPEAT the network test
Assist Control Module ( PAM ) with the scan tool. If the DTC returns, GO to
Pinpoint Test T .
U0159:00 Lost Communication With Parking ACM CLEAR the DTC. REPEAT the network test
Assist Control Module ( PAM ): with the scan tool. If the DTC returns, GO to
No Sub Type Information IPC Pinpoint Test T .
U0161:00 Lost Communication With IPC REFER to Section 413-01 .
Compass Module: No Sub Type
Information
U0162:00 Lost Communication With ACM REFER to Section 415-00 .
Navigation Display Module: No
Navigation Control Module: No with the scan tool. If the DTC returns, GO to
Sub Type Information Pinpoint Test N .
U0164 Lost Communication With HVAC FCIM CLEAR the DTC. REPEAT the network test
Control Module with the scan tool. If the DTC returns, GO to
FDIM Pinpoint Test V .
U0164:00 Lost Communication With HVAC ACM CLEAR the DTC. REPEAT the network test
Control Module: No Sub Type with the scan tool. If the DTC returns, GO to
Information IPC Pinpoint Test V .
U016A:00 Lost Communication With Global APIM CLEAR the DTC. REPEAT the network test
Positioning System Module: No with the scan tool. If the DTC returns, GO to
Sub Type Information Pinpoint Test P .
U0184 Lost Communication With Radio ( FCIM CLEAR the DTC. REPEAT the network test
ACM ) with the scan tool. If the DTC returns, GO to
FDIM Pinpoint Test M .
U0184:00 Lost Communication With Radio: APIM CLEAR the DTC. REPEAT the network test
No Sub Type Information with the scan tool. If the DTC returns, GO to
Audio DSP Pinpoint Test M .
module

FCIM
IPC
U0193 Lost Communication With Digital ACM REFER to Section 415-00 .
Audio Control Module ( SDARS )
FDIM
U0193:00 Lost Communication With Digital ACM REFER to Section 415-00 .
Audio Control Module ( SDARS ):
U0196 Lost Communication With ACM REFER to Section 415-00 .
Entertainment Control Module -
Rear (AUX) FDIM
Rear "A": No Sub Type Audio DSP
Information module
U0197 Lost Communication With ACM CLEAR the DTC. REPEAT the network test
Telephone Control Module with the scan tool. If the DTC returns, GO to
FDIM Pinpoint Test AA .
U0197:00 Lost Communication With ACM CLEAR the DTC. REPEAT the network test
Telephone Control Module: No with the scan tool. If the DTC returns, GO to
Sub Type Information Audio DSP Pinpoint Test AA .
module
U0208:00 Lost Communication With Seat IPC CLEAR the DTC. REPEAT the network test
Control Module "A": No Sub Type with the scan tool. If the DTC returns, GO to
Information Pinpoint Test Z .
U0232:00 Lost Communication With Side IPC CLEAR the DTC. REPEAT the network test
Obstacle Detection Control Module with the scan tool. If the DTC returns, GO to
- Left: No Sub Type Information Pinpoint Test R .
U0233:00 Lost Communication With Side IPC CLEAR the DTC. REPEAT the network test
Obstacle Detection Control Module with the scan tool. If the DTC returns, GO to
- Right: No Sub Type Information Pinpoint Test S .
U0238 Lost Communication With Digital ACM CLEAR the DTC. REPEAT the network test
Audio Control Module "D" ( DSP ) with the scan tool. If the DTC returns, GO to
FDIM Pinpoint Test W .
U0238:00 Lost Communication With Digital ACM CLEAR the DTC. REPEAT the network test
Audio Control Module "D" ( DSP with the scan tool. If the DTC returns, GO to
): No Sub Type Information Pinpoint Test W .
Headlamp Control Module "A": No with the scan tool. If the DTC returns, GO to
Sub Type Information Pinpoint Test I .
U0249 Lost Communication With ACM REFER to Section 415-00 .
Rear "B" ( RCU ) FDIM
Rear "B" ( RCU ): No Sub Type
Information
U0253:00 Lost Communication With RCM CLEAR the DTC. REPEAT the network test
Accessory Protocol Interface with the scan tool. If the DTC returns, GO to

Module: No Sub Type Information Pinpoint Test AA .

U0255 Lost Communication With Front ACM CLEAR the DTC. REPEAT the network test
Controls Interface Module with the scan tool. If the DTC returns, GO to
Pinpoint Test N .
U0255:00 Lost Communication With Front ACM CLEAR the DTC. REPEAT the network test
Display Interface Module: No Sub with the scan tool. If the DTC returns, GO to
Type Information APIM Pinpoint Test O .
U0256 Lost Communication With Front ACM CLEAR the DTC. REPEAT the network test
Display Interface Module with the scan tool. If the DTC returns, GO to
Pinpoint Test O .
U0256:00 Lost Communication With Front ACM CLEAR the DTC. REPEAT the network test
Controls Interface Module: No Sub with the scan tool. If the DTC returns, GO to
Type Information APIM Pinpoint Test N .
U0294:87 Lost Communication With TCM CLEAR the DTC. REPEAT the network test
Powertrain Control Monitor (Hybrid) with the scan tool. If the DTC returns, GO to
Module: Missing Message Pinpoint Test A .
U0298:00 Lost Communication With DC to BECM CLEAR the DTC. REPEAT the network test
DC Converter Control Module "A": with the scan tool. If the DTC returns, GO to
No Sub Type Information IPC Pinpoint Test L .
(Hybrid)
U029A:00 Lost Communication With Hybrid BECM REFER to Section 414-03 .
Battery Pack Sensor Module: No
U0401 Invalid Data Received from ECM 4X4 RETRIEVE and FOLLOW the DTCs from the
/PCM A control PCM.
module
ABS
module
U0401:00 Invalid Data Received from ECM ABS RETRIEVE and FOLLOW the DTCs from the
/PCM "A": No Sub Type module PCM.
Information
PSCM
RCM
U0401:66 Invalid Data Received from ECM BECM RETRIEVE and FOLLOW the DTCs from the
/PCM "A": Signal Has Too Many PCM.
Transitions / Events
U0401:68 Invalid Data Received from ECM ACCM RETRIEVE and FOLLOW the DTCs from the
/PCM "A": Event Information PCM.
BECM
DC/DC
IPC
U0401:86 Invalid Data Received from ECM HCM RETRIEVE and FOLLOW the DTCs from the
/PCM "A": Signal Invalid PCM.
U0402 Invalid Data Received from TCM ABS RETRIEVE and FOLLOW the DTCs from the
module TCM .

U0402:68 Invalid Data Received from TCM : BECM RETRIEVE and FOLLOW the DTCs from the
Event Information TCM .
IPC
U0402:86 Invalid Data Received from TCM : HCM RETRIEVE and FOLLOW the DTCs from the
Signal Invalid TCM .
U040A:68 Invalid Data Received from Air IPC RETRIEVE and FOLLOW the DTCs from the
Conditioning Control Module: ACCM .
Event Information
U0412:68 Invalid Data Received from Battery IPC RETRIEVE and FOLLOW the DTCs from the
Energy Control Module A: Event (Hybrid) BECM .
Information
U0412:81 Invalid Data Received from Battery TCM RETRIEVE and FOLLOW the DTCs from the
Energy Control Module A: Invalid (Hybrid) BECM .
Serial Data Received
U0414 Invalid Data Received From ABS RETRIEVE and FOLLOW the DTCs from the
Four-Wheel Drive Clutch Control module 4X4 control module.
Module
U0415 Invalid Data Received From 4X4 RETRIEVE and FOLLOW the DTCs from the
Anti-Lock Brake System (ABS) control ABS module.
Control Module module
U0415:00 Invalid Data Received From PSCM RETRIEVE and FOLLOW the DTCs from the
Anti-Lock Brake System (ABS) ABS module.
Information
U0415:68 Invalid Data Received from IPC RETRIEVE and FOLLOW the DTCs from the
Control Module: Event Information
U0415:86 Invalid Data Received from HCM RETRIEVE and FOLLOW the DTCs from the
Control Module: Signal Invalid
U0420:87 Invalid Data Received From Power ABS RETRIEVE and FOLLOW the DTCs from the
Steering Control Module: Missing module PSCM .
Message
U0422:00 Invalid Data Received From Body GPSM RETRIEVE and FOLLOW the DTCs from the
Control Module: No Sub Type SJB .
Information
U0422:68 Invalid Data Received From Body HVAC RETRIEVE and FOLLOW the DTCs from the
Control Module: Event Information module SJB .
IPC
U0423:00 Invalid Data Received From APIM RETRIEVE and FOLLOW the DTCs from the
Instrument Panel Cluster ( IPC ) IPC .
Control Module: No Sub Type GPSM
Information
U0423:64 Invalid Data Received From ABS RETRIEVE and FOLLOW the DTCs from the
Instrument Panel Cluster ( IPC ) module IPC .
Control Module: Signal Plausibility
Failure
U0423:68 Invalid Data Received From ACCM RETRIEVE and FOLLOW the DTCs from the
Control Module: Event Information HVAC

module
U0423:86 Invalid Data Received From HCM RETRIEVE and FOLLOW the DTCs from the
Control Module: Signal Invalid
U0424:68 Invalid Data Received From BECM RETRIEVE and FOLLOW the DTCs from the
HVAC Control Module: Event HVAC module.
Information
U0428:86 Invalid Data Received From HCM RETRIEVE and FOLLOW the DTCs from the
Steering Angle Sensor Module: PSCM .
Signal Invalid
U0430:68 Invalid Data Received From Tire HVAC RETRIEVE and FOLLOW the DTCs from the
Pressure Monitor Module: Event module SJB .
Information
U0442:86 Invalid Data Received From ECM OCSM RETRIEVE and FOLLOW the DTCs from the
/PCM "B": Signal Invalid PCM.
U0452:00 Invalid Data Received from BECM RETRIEVE and FOLLOW the DTCs from the
Restraints Control Module A: No RCM .
U0452:29 Invalid Data Received from ABS RETRIEVE and FOLLOW the DTCs from the
Restraints Control Module A: module RCM .
Signal Invalid
U0452:68 Invalid Data Received from IPC RETRIEVE and FOLLOW the DTCs from the
Restraints Control Module A: RCM .
Event Information
U0452:86 Invalid Data Received From OCSM RETRIEVE and FOLLOW the DTCs from the
Restraints Control Module A: RCM .
Signal Invalid
U0462:00 Invalid Data Received From IPC REFER to Section 413-01 .
Compass Module: No Sub Type
Information
U0462:68 Invalid Data Received From IPC REFER to Section 413-01 .
Compass Module: Event
Information
U046B:00 Invalid Data Received From Global APIM RETRIEVE and FOLLOW the DTCs from the
Positioning System Module: No GPSM .
U0485:00 Invalid Data Received From Radio: APIM RETRIEVE and FOLLOW the DTCs from the
No Sub Type Information ACM .
U0533:68 Invalid Data Received from Side IPC RETRIEVE and FOLLOW the DTCs from the
Obstacle Detection Control Module SOD-L .
- Left: Event Information
U0534:68 Invalid Data Received from Side IPC RETRIEVE and FOLLOW the DTCs from the
Obstacle Detection Control Module SOD-R .
- Right: Event Information
U0599:68 Invalid Data Received from DC to BECM RETRIEVE and FOLLOW the DTCs from the
DC Converter Control Module "A": DC/DC .
Event Information IPC
(Hybrid)
U1900

CAN Communication Bus ABS GO to Symptom Chart for module that failed
Fault-Receive Error module network test.
U2023 Fault Received From External ABS The module had an invalid network
Node module input/message from another module.
RETRIEVE and FOLLOW the non-network
DTCs from other modules. REFER to Section
419-10 .
U2472 Unexpected Ignition State SJB REFER to Section 419-10 .
U2473 Unexpected Vehicle Speed SJB REFER to Section 419-10 .
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: The PCM Does Not Respond To The Scan Tool
Refer to Wiring Diagrams Cell 14 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Module Communications
Network for schematic and connector information.
- 2.5L for schematic and connector information.
Normal Operation
The PCM communicates with the scan tool through the High Speed Controller Area Network (HS-CAN).
Circuits VDB04 (WH/BU) ( HS-CAN +) and VDB05 (WH) ( HS-CAN -) provide the network connection to
the PCM. An Integrated Diagnostic System (IDS) session cannot be established if the PCM communication
fails when attempting to identify the vehicle.
PCM
PINPOINT TEST A: THE PCM DOES NOT RESPOND TO THE SCAN TOOL

Section 414-01 .

A1 VERIFY WHETHER OTHER HS-CAN MODULES PASS
THE NETWORK TEST
Yes
• Enter the following diagnostic mode on the scan tool: Network If "pass" or a DTC was listed
Test . next to the PCM, a network fault
• In the LH pane of the IDS network test display screen, verify is not currently present. GO to
whether any HS-CAN modules passed the network test. Pinpoint Test AE to diagnose an
• Is the text "pass" or a DTC listed next to any of the intermittent HS-CAN fault
following modules (if equipped): 4X4 control module, ABS condition.
module, ACCM (Hybrid only), Accessory Protocol
Interface Module (APIM), Battery Energy Control Module If "pass" or a DTC was listed
(BECM) (Hybrid only), DC/DC (Hybrid only), Headlamp next to one or more modules
Control Module (HCM), Instrument Panel Cluster (IPC), other than the PCM, GO to A2 .
Power Steering Control Module (PSCM), Restraints
Control Module (RCM), Occupant Classification System No
Module (OCSM), PCM or Transmission Control Module No modules are currently
(TCM)? communicating on the HS-CAN
. GO to Pinpoint Test AD to
diagnose no HS-CAN
communication.
A2 VERIFY THE PC/ED MANUAL PINPOINT TEST QA HAS
BEEN CARRIED OUT
Yes
• Verify that the Powertrain Control/Emissions Diagnosis GO to A3 .
(PC/ED) manual pinpoint test QA has been carried out.
• Has pinpoint test QA been carried out? No
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual, Section 5,
pinpoint test QA to diagnose no
communication with the PCM.
A3 CHECK THE HS-CAN TERMINATION RESISTANCE
Yes
• Ignition OFF. CONNECT the negative battery
• Disconnect: Negative Battery Cable . cable. GO to A7 .
• Measure the resistance between the DLC C251-6, circuit
VDB04 (WH/BU), harness side and the DLC C251-14, circuit No
VDB05 (WH), harness side. For 2.5L gasoline and 3.0L
engines, GO to A4 .
For 3.5L engine, GO to A5 .
For 2.5L hybrid engine, GO to

A6 .
PINPOINT TEST A: THE PCM DOES NOT RESPOND TO THE SCAN TOOL 6266
A4 CHECK THE HS-CAN CIRCUITS BETWEEN THE PCM

AND THE DLC FOR AN OPEN - 2.5L GAS AND 3.0L
Yes
• Disconnect: PCM C175b . CONNECT the negative battery
• Measure the resistance between the PCM C175b-59, circuit cable. GO to A7 .
VDB04 (WH/BU), harness side and the DLC C251-6, circuit
VDB04 (WH/BU), harness side. No
CONNECT the negative battery
cable. CLEAR the DTCs.
REPEAT the network test with
the scan tool.
• Measure the resistance between the PCM C175b-58, circuit

VDB05 (WH), harness side and the DLC C251-14, circuit
VDB05 (WH), harness side.

AND THE DLC FOR AN OPEN - 3.5L
Yes
the scan tool.
• Measure the resistance between the PCM C175b-3, circuit


AND THE DLC FOR AN OPEN - 2.5L HYBRID
Yes
the scan tool.
• Measure e resistance between the PCM C175b-43, circuit


A7 CHECK FOR CORRECT PCM OPERATION
Yes
• Disconnect all the PCM connectors. INSTALL a new PCM. REFER
• Check for: to the appropriate section in
♦ corrosion Section 303-14A , Section
♦ damaged pins 303-14B or Section 303-14C .
♦ pushed-out pins CLEAR the DTCs. REPEAT the
• Connect all the PCM connectors and make sure they seat network test with the scan tool.
correctly.
the scan tool.
Pinpoint Test B: The ABS Module Does Not Respond To The Scan Tool
Refer to Wiring Diagrams Cell 14 ( Fusion/MKZ , Fusion Hybrid/MKZ Hybrid ), Module Communications
Network for schematic and connect

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2012 Fusion, MKZ, Fusion Hybrid, MKZ Hybrid Workshop Manual

35. NOTE: LH shown, RH similar.

Remove the 2 front subframe nuts.

36. Lower the subframe assembly from the vehicle.

37. Remove the 2 fasteners and the inspection cover.

38. Remove and discard the 4 torque converter nuts.

SECTION 307-01A: Automatic 2012 Fusion, MKZ, Fusion Hybrid, MKZ

Torque Converter Hub Seal

Installer, Fluid Pump Seal

Remover, Input Shaft Oil Seal

2. Remove the torque converter.

1. Position the torque converter hub seal in place.

Torque Converter Hub Seal 3501

3. Install the torque converter.

Torque Converter Hub Seal 3502

SECTION 307-01A: Automatic 2012 Fusion, MKZ, Fusion Hybrid, MKZ

2. Remove the torque converter.

1. Install the torque converter.

Torque Converter 3503

Torque Converter 3504

SECTION 307-01A: Automatic 2012 Fusion, MKZ, Fusion Hybrid, MKZ

Eye, Engine Lift

Bar, Engine Spreader

Powertrain Lift With Tilting Plate

Support Bar, Engine

Vehicle Communication Module (VCM)

1. Secure the transaxle to a suitable transmission jack with a safety strap.

3. Position the transaxle to the back of the engine.

4. Install the 7 transaxle-to-engine bolts.

6. Install 4ew torque converter nuts.

7. Position the inspection cover in place and install the 2 fasteners.

9. NOTE: LH shown, RH similar.

Install the 2 front subframe nuts.

• Tighten to 150 Nm (111 lb-ft).

10. NOTE: LH shown, RH similar.

Position the subframe brackets and install the 4 bolts finger-tight.

11. NOTE: LH shown, RH similar.

Install the 2 rear subframe nuts.

• Tighten to 150 Nm (111 lb-ft).

Tighten the 4 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).

Position the steering gear.

1. Install the 3 steering gear mounting bolts.

14. Install the 3 power steering return line bolts.

15. NOTE: LH shown, RH similar.

Install the stabilizer bar links and nuts to the struts.

• Tighten to 40 Nm (30 lb-ft).

16. NOTE: LH shown, RH similar.

Install the tie-rod ends and nuts.

• Tighten to 48 Nm (35 lb-ft).

Install the 2 roll restrictor bracket bolts.

• Tighten to 90 Nm (66 lb-ft).

All-Wheel Drive (AWD) vehicles

Front Wheel Drive (FWD)

30. Install the 4 upper transaxle-to-engine bolts.

33. Connect the Transmission Control Module (TCM) electrical connector.

35. Connect the selector lever cable end.

36. Remove the transmission fluid fill plug.